Senior Mechanical Engineer
Confirmed on the employer's own hiring board on Oct 17, 2026. First seen by Alion on Dec 22, 2025. Dexmate scores A on the Alion truth index.
About Dexmate
Dexmate is building the foundation for physical AI - combining a new generation of robots with a universal Physical AI OS, making robots as easy to build and deploy as software. Today, robotics is fragmented, slow, and closed: most builders are forced to reinvent the same stack again and again, and most ideas never make it past the prototype stage. We exist to change that. Our mission is to democratize robotics by lowering the barrier to entry, delivering a plug-and-play platform for developers, researchers, and enterprises, and cultivating an open ecosystem that accelerates the evolution of physical AI.
If you want to help shape the next layer of human capability - and believe the future of robotics should be built together, not in isolation - we'd love to build it with you.
The Role
We are looking for a Senior Mechanical Engineer to design, test, and implement key hardware components for our humanoid robot platform. You will own mechanical subsystems end-to-end - from requirements definition through 3D CAD, prototype build, supplier qualification, first-article inspection, and production release.
This is a hands-on role that spans the full development arc - from first prototype on the bench to production-ready design at a contract manufacturer. You will own the transition: designing for manufacturability from day one, driving DFM reviews, resolving first-article failures, and ensuring your designs survive the gap between "works in the lab" and "ships at volume." You will work alongside electrical, firmware, and controls engineers daily, and your designs will be on every unit that leaves the factory.
Responsibilities
Design parts and assemblies in 3D CAD that satisfy load conditions, form factor constraints, range-of-motion requirements, and durability targets
Determine component-level mechanical requirements (stiffness, strength, fatigue, thermal) from system-level functional specs
Apply analytical methods - FEA, tolerance stack-up, kinematic analysis - before releasing designs for prototyping or production
Generate accurate 2D drawings with GD&T per ASME Y14.5 appropriate for both prototype and production inspection methods
Build prototypes to test assembly, range of motion, wire routing, and integration with adjacent subsystems
Design and build test stands and fixtures; conduct structured validation testing and document results rigorously
Own the prototype-to-production transition for your subsystems: apply DFM/DFA principles from the first design iteration, not as a final step; drive design changes required to achieve manufacturability, yield, and cost targets
Work with suppliers to select and qualify parts; inspect first articles, perform root cause analysis on failures, and drive corrective action through to closure
Conduct DFM/DFA reviews with contract manufacturers; define and own the mechanical acceptance criteria, support tooling bring-up, and stay engaged through production ramp
Define and execute structured validation plans - including environmental, fatigue, and functional testing - to prove out designs before they lock for production
Collaborate closely with electrical engineers on electromechanical integration - motor mounting, sensor placement, wire harness routing, connector access
Contribute to materials selection, surface finishing, and manufacturing process decisions across the robot
Minimum Qualifications
5+ years of mechanical engineering experience in robotics, industrial automation, automotive, aerospace, or consumer electronics - with at least one product shipped to production
Expert proficiency in 3D CAD (SolidWorks, NX, CATIA, Onshape, or equivalent) for complex parts and assemblies with tight tolerances
Mastery of GD&T per ASME Y14.5 and the ability to create production-ready 2D drawings
Experience with actuators and transmission systems: strain-wave (harmonic), planetary, cycloidal gearing, or direct-drive
Hands-on experience with structural analysis (FEA) and tolerance stack-up analysis as part of routine design validation
Proven electromechanical integration experience: motors, sensors, encoders, wire harnesses, and connectors in tight mechanical envelopes
Demonstrated ability to take a mechanical design from working prototype to production-ready - including DFM iterations, supplier qualification, first-article inspection, and manufacturing yield validation; candidates who have only operated in R&D or prototype-only environments are not a fit for this role
Preferred Qualifications
Deep familiarity with modern manufacturing processes and when to apply each: CNC machining (3- and 5-axis), injection molding, die casting, sheet metal fabrication, MIM (metal injection molding), investment casting, and surface finishing processes (anodizing, PVD, powder coat); understanding of process tradeoffs across cost, tolerance, lead time, and volume
Direct experience working with contract manufacturers: DFM reviews, tooling bring-up, first-article inspection, and yield improvement
Hands-on prototyping experience with rapid fabrication methods - FDM/SLA/SLS 3D printing, CNC soft tooling, urethane casting - and inspection equipment including CMM, optical comparators, and CT scanning for first-article validation
Experience with thermal design and heat dissipation in compact electromechanical systems
Background in reliability engineering: fatigue analysis, HALT/HASS, or accelerated life testing
Wire harness design experience
Proficiency with simulation tools beyond FEA: CFD, multi-body dynamics (Adams, Simscape), or kinematic simulation
Familiarity with functional safety requirements for mechanisms operating near humans