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Sr Mechanical Engineer, Fan and Duct Design

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Figure

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Location:
United States , San Jose

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Category:
IT - Software Development

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Contract Type:
Not provided

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Salary:

160000.00 - 200000.00 USD / Year
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Job Description:

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.

Job Responsibility:

  • Own the mechanical design of the robot’s fan assemblies: impellers, housings, ducts, diffusers, seals, shrouds, baffles, and mounting structures
  • Translate CFD-engineered impeller geometry into fully detailed, moldable components with proper drafts, ribs, gates, cooling channels, and tooling strategies
  • Develop manufacturable plastic parts (injection-molded), metal components, and hybrid structures for quiet, efficient airflow
  • Select, qualify, and integrate fan motors including BLDC, slotless motors, PMSMs, or custom motor architectures depending on system targets
  • 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
  • Support thermal and acoustic engineers by designing test fixtures, running airflow tests, and validating fan performance
  • Own iterative cycles: prototype → measure → redesign → retest
  • Drive supplier engagement on tooling, gating, draft strategies, warpage control, and tolerance analyses
  • Partner with GSM and CMs to close out DFM, tooling release, mold trials, and FAIs
  • Create drawing packages, GD&T, BOMs, and assembly instructions for production
  • Collaborate with CFD, thermal, acoustics, system architecture, IDand manufacturing teams to converge on a highly optimized fan system
  • Work with global suppliers to evaluate materials, molding processes, motor options, and assembly methods
  • Provide hands-on build support for engineering units and early factory runs

Requirements:

  • 5+ years experience in mechanical engineering, electromechanical design, turbomachinery components, or similar
  • Bachelor’s or Master’s in Mechanical Engineering, Mechatronics, Aerospace, or related field
  • Expert in 3D CAD modeling and surfacing
  • comfort with complex geometries derived from CFD
  • Deep understanding of mechanical design for airflow systems: fans, ducts, impellers, shrouds, or related components
  • Experience turning CFD geometry into manufacturable CAD suitable for tooling
  • Familiar with experimental methods for measuring flow, pressure, and acoustic performance
  • Strong DFM knowledge for injection molding, tooling, and assembly
  • Ability to write clear documentation, test plans, and release packages

Nice to have:

  • Experience with small BLDC fan motors, custom motor sourcing, or electromechanical integration
  • Background in acoustics, noise reduction, vibration isolation, or fan blade noise characterization
  • Experience with high-volume plastic injection molding and tool releases
  • CATIA V6 experience

Additional Information:

Job Posted:
January 05, 2026

Employment Type:
Fulltime
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