Senior Design Engineer

Senior Design Engineer Summary Headquartered in sunny Los Angeles, GrayMatter Robotics is a well-capitalized AI robotics startup serving the manufacturing industry. We empower shop floor workers with our smart robots that assist with tedious and ergonomically challenging tasks, specifically in automated surface finishing. Our proprietary GMR-AI™ software is integrated with state-of-the-art industrial robots, sensors, and tools to create application-specific turnkey solutions for customers through a Robot-as-a-Service (RaaS) model. We help manufacturers improve the quality of life for their workforce while increasing production capacity, and reducing scrap, repair, and rework costs. As a Senior Design Engineer, you will join our Design & Mechatronics team onsite in our Carson, CA office to explore, develop and test novel systems in house for implementation in the field. Role & Responsibilities - Robotic Hardware Design: Design hardware and mechanisms for robotic systems, including system architectures, developing and reviewing new concepts with a primary focus on performance and reliability. - EOAT Design & DFM Compliance: Collaborate with cross-functional teams to drive product improvements focusing on DFM (Design for Manufacturing) for End-of-Arm Tooling (EOAT) while ensuring compliance with ISO/TR 20218-1 safety guidelines. - Advanced FEA & Simulation: Conduct complex Finite Element Analysis (FEA) and thermal simulations to validate structural integrity, predict failure modes, and optimize geometry before fabrication. - Structural Analysis: Perform foundational structural analysis and simulation to validate design integrity. - Rapid Prototyping: Prototype hardware considering Design for Manufacturability (DFM), utilizing tools such as 3D printers and CNC machines where appropriate. - Hardware Selection: Own the selection process for distinct electrical, mechanical, and pneumatic hardware components. - System Integration: Collaborate closely with Electrical and Software teams to ensure seamless integration of motors, sensors, and cabling within the mechanical assembly. - System Troubleshooting & Optimization: Troubleshoot and test existing hardware and automation systems to identify opportunities for robustness and significant improvements. - Root Cause Analysis: Lead formal root cause investigations (e.g., 8D, Fishbone, 5 Whys) for field failures or manufacturing defects to implement permanent corrective actions. - Safety Compliance & Risk Assessment: Lead mechanical risk assessments (RA) and ensure system designs adhere to core industrial safety standards, including ISO 10218-1/-2 and ANSI/A3 R15.06. - Design and Tolerance: Effectively implement GD&T (Geometric Dimensioning and Tolerancing), Tolerance Analysis, Design for Manufacturing, Design for Assembly. - Collaboration: Collaborate cross-functionally with internal and external teams to define customer requirements, validate project feasibility, and coordinate material procurement for in-house testing prior to deployment. - BOM & Inventory Management: Organize part number allocation and review Bills of Materials (BOMs) for completeness to actively support inventory management and system deployment as well as maintaining an accurate BOM in PDM. - Cost Reduction Initiatives: Execute Value Analysis/Value Engineering (VAVE) efforts to reduce Bill of Materials (BOM) costs without compromising system performance or reliability. - Vendor Technical Management: Manage relationships with external machine shops and component suppliers to ensure part quality, lead time adherence, and cost-effectiveness. - Validation Strategy: Make strategic recommendations for design validation and testing protocols. - Lifecycle Management: Oversee the full mechanical product lifecycle from initial conceptualization through mass production and end-of-life support. - Mentorship: Lead, mentor, and actively develop junior talent within the engineering team. Minimum Qualifications ... (truncated, view full listing at source)