Senior Gear Design Engineer
Full Job Posting
Responsibilities:
- Own gear design end-to-end: system-level sizing, macro and micro geometry definition, rating and life analysis, prototyping, validation, and ramp to mass production.
- Perform gear sizing, contact/bending stress analysis, and micro-geometry optimization (profile and lead modifications) in KISSsoft to meet efficiency, durability, backlash, and NVH targets.
- Design gears, shafts, and transmission assemblies in 3D CAD (CATIA) that satisfy extreme packaging, load, and durability requirements of a high-DOF robotic hand.
- Define gear manufacturing strategy — cutting, grinding, powder metal, MIM, or plastics — and drive DFM with suppliers from first articles through high-volume production.
- Generate accurate 2D drawings with gear data tables and GD&T per ASME Y14.5, and define inspection and metrology plans for incoming quality.
- Build and run test rigs to characterize efficiency, backlash, wear, and fatigue life; correlate test data back to analytical models.
- Collaborate closely with actuator, structures, EE, and manufacturing teams — proactively identifying risks, driving decisions, and unblocking the program without waiting to be asked.
Requirements:
- 7+ years of experience designing gears and geared transmissions
- Bachelor's or Master's Degree in Mechanical Engineering, Robotics, Mechatronics, or similar field
- Demonstrated ownership of complete gear designs from initial sizing through mass manufacturing
- Proficiency in KISSsoft (or equivalent) for gear rating, contact analysis, and micro-geometry optimization
- Proficiency in CATIA (or equivalent high-end 3D CAD) for complex geometry and large assemblies
- Working knowledge of AGMA/ISO gear rating standards, gear metrology, and tolerancing
- Experience with gear manufacturing processes (hobbing, shaping, skiving, grinding, powder metal, MIM, or injection molding) and supplier development
- A strong team player with a high sense of agency — you take ownership of outcomes, communicate openly, and elevate the people around you
- Bonus Qualifications:
- Experience with small-module, high-ratio, or high-power-density gearing (planetary, cycloidal, or strain wave)
- Experience in robotics, surgical devices, aerospace actuation, or automotive e-drive transmissions
- Familiarity with lubrication selection, grease DOE, and tribology for compact gearboxes
- Experience with fatigue modeling, bearing life characterization, and accelerated life testing
- Experience taking a product through NPI builds (EVT/DVT/PVT) and FATP at volume
- The US base salary range for this full -time position is between $160,000 - $250,000 annually.
- 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.
About Figure
AI robotics company developing general-purpose humanoid robots designed to work alongside people in real-world environments.
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