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Robotics, Artificial Intelligence, Automation, Manufacturing.

Senior Gear Design Engineer

San Jose, CAOnsiteFull TimeSenior$160,000–$250,000 /yrPosted 2 months agoVisa sponsorship available

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Required skills

  • gear design
  • transmission design
  • system-level sizing
  • macro geometry
  • micro geometry
  • rating and life analysis
  • prototyping
  • validation
  • mass production
  • KISSsoft

Nice to have

  • small-module gearing
  • high-ratio gearing
  • high-power-density gearing
  • planetary gears
  • cycloidal gears
  • strain wave gears

Role summary

Figure, an AI robotics company, is seeking a Senior Gear Design Engineer in San Jose, CA. This role requires 5 days/week in-office collaboration to own the end-to-end design of gears and transmissions for humanoid robot hands. Responsibilities include system-level sizing, stress analysis, CAD design, manufacturing strategy definition, and validation through mass production. The ideal candidate will have 7+ years of experience, proficiency in KISSsoft and CATIA, and knowledge of gear manufacturing processes and standards. Experience with high-power-density gearing and robotics is a plus.

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.

We are looking for a Senior Gear Design Engineer to own gear and transmission design for our humanoid robot's hands — some of the most power-dense, space-constrained actuators in the world. You will take gear trains from first-principles sizing through validation and into mass manufacturing, defining how our robot grasps and manipulates the world.

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 $160,000 to $250,000 per year.

    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.

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