Staff Design Engineer

GrayMatter Robotics•Carson, CA

8d•$135,000 - $250,000•Onsite

About The Position

GrayMatter Robotics is a well-capitalized Physical AI company headquartered in Los Angeles. It builds Factory SuperIntelligence through robotic systems that learn, adapt, and develop process intelligence. Its systems are in active production, performing demanding manufacturing work, and are delivered through a Robots-as-a-Service model. The Staff Design Engineer will join the Design & Mechatronics team onsite at the Carson, California office to explore, develop, and test novel systems for field implementation. The role spans robotic hardware design, simulation and analysis, prototyping, system integration, troubleshooting, safety, manufacturing readiness, and product lifecycle support. It also includes leading root-cause investigations, mentoring junior engineers, and working with internal teams, customers, machine shops, and suppliers. The position is planned as a Q3/Q4 2026 hire.

Requirements

BS/MS in Mechanical Engineering or equivalent experience.
Demonstrated experience with 3D solid modeling, analysis, and development of 2D manufacturing drawings.
Thorough understanding of manufacturing processes, including manual machining, CNC machining, welding, sheet-metal fabrication, and plastic 3D prototyping.
Thorough understanding of materials for manufacturing.
At least 8 years of working proficiency with CAD programs, hands-on prototyping, fabrication, or the ability to design for 3D printing.
Strong communication skills and ability to collaborate effectively across multiple teams and with customers.
Willingness to work at an early-stage company with dynamic priorities.
Ability to conduct root-cause corrective actions (RCCAs) and trade studies.
Ability to solve problems effectively in a collaborative environment.

Nice To Haves

At least 8 years of working proficiency with SolidWorks.
Experience with industrial robots and six-degree-of-freedom robotic arms.
Experience with machining, rapid prototyping, and fabrication processes and materials to meet functional design requirements.
Experience with project management.
Experience with product deployment.
Familiarity with industrial facilities and equipment.

Responsibilities

Design hardware, mechanisms, and system architectures for robotic systems, developing and reviewing concepts with a focus on performance and reliability.
Collaborate across functions to improve End-of-Arm Tooling (EOAT) and ensure Design for Manufacturing (DFM) compliance and adherence to ISO/TR 20218-1 safety guidelines.
Conduct complex finite element analysis (FEA), thermal simulations, and structural analysis to validate designs, predict failure modes, and optimize geometry before fabrication.
Prototype hardware with manufacturability in mind, using tools such as 3D printers and CNC machines where appropriate.
Own selection of electrical, mechanical, and pneumatic hardware components.
Coordinate with Electrical and Software teams to integrate motors, sensors, and cabling into mechanical assemblies.
Troubleshoot and test existing hardware and automation systems to improve robustness and performance.
Lead formal root-cause investigations, such as 8D, Fishbone, and 5 Whys, for field failures or manufacturing defects and implement permanent corrective actions.
Lead mechanical risk assessments and ensure designs adhere to industrial safety standards, including ISO 10218-1/-2 and ANSI/A3 R15.06.
Apply GD&T, tolerance analysis, Design for Manufacturing, and Design for Assembly practices.
Work with internal and external teams to define customer requirements, assess project feasibility, and coordinate materials procurement for in-house testing before deployment.
Organize part-number allocation and review Bills of Materials for completeness; support inventory management and system deployment and maintain accurate BOMs in PDM.
Execute Value Analysis/Value Engineering initiatives to reduce BOM costs without compromising performance or reliability.
Manage machine-shop and component-supplier relationships to ensure part quality, lead-time adherence, and cost-effectiveness.
Recommend design-validation strategies and testing protocols.
Oversee the mechanical product lifecycle from conceptualization through mass production and end-of-life support.
Lead, mentor, and develop junior engineering talent.