Staff Design Engineer

Summary GrayMatter Robotics is a well-capitalized Physical AI company headquartered in Los Angeles, building Factory SuperIntelligence (FSI) through systems that learn, adapt, and develop genuine process intelligence across every part they touch. Our robots take on the tedious, hazardous, and ergonomically demanding work that has kept manufacturing dependent on a shrinking skilled workforce, delivering superhuman performance. Robotics has a demo problem. GMR doesn't. Our systems are in active production today, adapting autonomously to real geometries, real materials, and real process variation without reprogramming. We deliver our system through a Robots-as-a-Service (RaaS) model that converts capital expenditure into an operating subscription, making Physical AI accessible to the manufacturers who need it most. We hire people who want to solve hard physical problems at an industrial scale. We help manufacturers improve the quality of life for their workforce while increasing production capacity, and reducing scrap, repair, and rework costs. As a Senior Design Engineer, you will join our Design & Mechatronics team onsite in our Carson, CA office to explore, develop and test novel systems in house for implementation in the field. Role & Responsibilities Robotic Hardware Design: Design hardware and mechanisms for robotic systems, including system architectures, developing and reviewing new concepts with a primary focus on performance and reliability. EOAT Design & DFM Compliance: Collaborate with cross-functional teams to drive product improvements focusing on DFM (Design for Manufacturing) for End-of-Arm Tooling (EOAT) while ensuring compliance with ISO/TR 20218-1 safety guidelines. Advanced FEA & Simulation: Conduct complex Finite Element Analysis (FEA) and thermal simulations to validate structural integrity, predict failure modes, and optimize geometry before fabrication. Structural Analysis: Perform foundational structural analysis and simulation to validate design integrity. Rapid Prototyping: Prototype hardware considering Design for Manufacturability (DFM), utilizing tools such as 3D printers and CNC machines where appropriate. Hardware Selection: Own the selection process for distinct electrical, mechanical, and pneumatic hardware components. System Integration: Collaborate closely with Electrical and Software teams to ensure seamless integration of motors, sensors, and cabling within the mechanical assembly. System Troubleshooting & Optimization: Troubleshoot and test existing hardware and automation systems to identify opportunities for robustness and significant improvements. Root Cause Analysis: Lead formal root cause investigations (e.g., 8D, Fishbone, 5 Whys) for field failures or manufacturing defects to implement permanent corrective actions. Safety Compliance & Risk Assessment: Lead mechanical risk assessments (RA) and ensure system designs adhere to core industrial safety standards, including ISO 10218-1/-2 and ANSI/A3 R15.06.