Sr Mechanical Engineer, Fan and Duct Design

<p>Figure is an AI robotics company developing autonomous general-purpose humanoid robots. The goal of the company is to ship humanoid robots with human level intelligence. Its robots are engineered to perform a variety of tasks in the home and commercial markets. Figure is headquartered in San Jose, CA.</p> <p>We are seeking a Senior Mechanical Engineer focused on Fan and Duct Design to own the end-to-end development of the robot’s airflow systems from early impeller geometry prototypes to production-ready assemblies released to manufacturing.</p> <p><strong>Responsibilities:</strong></p> <ul> <li>Own the mechanical design of the robot’s fan assemblies: impellers, housings, ducts, diffusers, seals, shrouds, baffles, and mounting structures.</li> <li>Translate CFD-engineered impeller geometry into fully detailed, moldable components with proper drafts, ribs, gates, cooling channels, and tooling strategies.</li> <li>Develop manufacturable plastic parts (injection-molded), metal components, and hybrid structures for quiet, efficient airflow.</li> <li>Select, qualify, and integrate fan motors including BLDC, slotless motors, PMSMs, or custom motor architectures depending on system targets.</li> <li>Collaborate with motor vendors and CMs to determine winding specs, bearings, back-EMF constants, and long-life design constraints with additional support from the Figure motor team</li> <li>Support thermal and acoustic engineers by designing test fixtures, running airflow tests, and validating fan performance.</li> <li>Own iterative cycles: prototype → measure → redesign → retest.</li> <li>Drive supplier engagement on tooling, gating, draft strategies, warpage control, and tolerance analyses.</li> <li>Partner with GSM and CMs to close out DFM, tooling release, mold trials, and FAIs.</li> <li>Create drawing packages, GDT, BOMs, and assembly instructions for production.</li> <li>Collaborate with CFD, thermal, acoustics, system architecture, IDand manufacturing teams to converge on a highly optimized fan system.</li> <li>Work with global suppliers to evaluate materials, molding processes, motor options, and assembly methods.</li> <li>Provide hands-on build support for engineering units and early factory runs.</li> </ul> <p><strong>Requirements: </strong></p> <ul> <li>5+ years experience in mechanical engineering, electromechanical design, turbomachinery components, or similar.</li> <li>Bachelor’s or Master’s in Mechanical Engineering, Mechatronics, Aerospace, or related field.</li> <li>Expert in 3D CAD modeling and surfacing; comfort with complex geometries derived from CFD.</li> <li>Deep understanding of mechanical design for airflow systems: fans, ducts, impellers, shrouds, or related components.</li> <li>Experience turning CFD geometry into manufacturable CAD suitable for tooling.</li> <li>Familiar with experimental methods for measuring flow, pressure, and acoustic performance.</li> <li>Strong DFM knowledge for injection molding, tooling, and assembly.</li> <li>Ability to write clear documentation, test plans, and release packages.</li> </ul> <p><strong>Bonus Qualifications: </strong></p> <ul> <li>Experience with small BLDC fan motors, custom motor sourcing, or electromechanical integration.</li> <li>Background in acoustics, noise reduction, vibration isolation, or fan blade noise characterization.</li> <li>Experience with high-volume plastic injection molding and tool releases.</li> <li>CATIA V6 experience.</li> </ul> <p>The US base salary range for this full-time position is between $160,000 - $200,000 annually.</p> <p>The pay offered for this position may vary based on several individual factors, including job-related knowledge, skills, and experience. The total compensation package may also include additional components/benefits depending on the specific role. This information will be shared if an employment offer is extended. </p>