We are seeking a highly experienced Lead Design Engineer to lead the design and manufacturing development of precision actuators for robotic systems. The ideal candidate will have strong expertise in gearbox design, transmission systems, gear calculations, and manufacturing process planning, with the ability to translate heavy-duty gearbox knowledge into compact, high-precision robotic actuator systems. This role will focus on developing high-torque-density, lightweight, and precision transmission systems used in robotic joints such as hip, knee, shoulder, and elbow assemblies.
Why Gearbox
Experience is Critical for Robotics Actuators? Your gearbox experience directly contributes to:
Planetary gear reduction system design
Shaft and bearing life calculations
Gear rating and safety validation (AGMA / ISO standards)
Manufacturing stage drawing & process planning
Precision assembly support Key Responsibilities 1.
Actuator Transmission
Design
Lead design of precision planetary and harmonic-like gear reduction systems for robotic actuators.
Develop compact, lightweight transmission systems for humanoid robot joints.
Perform torque density optimization and reduction ratio selection.
Design shafts, gears, bearings, and housing for high accuracy applications.
2.
Engineering
Calculations & Validation
Perform
Gear rating calculations
Shaft safety analysis
Bearing life estimation
Torsional stiffness analysis
Use KISSsoft / KISSsys for gear system validation.
Optimize backlash and precision performance.
Ensure compliance with ISO / AGMA standards.
3.
Manufacturing
Development
Develop gear manufacturing process plans for precision gears.
Design jigs & fixtures for actuator assembly.
Support precision machining and heat treatment processes.
Ensure tolerance stack-up analysis for high-accuracy systems.
- Prototype & Testing Support
Support actuator prototype builds.
Work closely with motor integration team.
Troubleshoot assembly and performance issues.
Improve efficiency, noise reduction, and vibration control.
- PLM, Documentation & Systems
Create GA, sectional, and detailed manufacturing drawings.
Manage BOM using PLM/PDM systems (Teamcenter / Windchill / EPDM).
Coordinate ERP integration with SAP / Oracle.
- Cross-Functional Leadership
Collaborate with
Motor design team
Electronics team
Control systems team
Manufacturing team
Guide and mentor junior engineers.
Lead design reviews and technical validation sessions.
Required
Qualifications
B.E.
Mechanical
Engineering
10+ years experience in gearbox / transmission design
Strong knowledge of
Planetary gear systems
Shaft & bearing calculations
Gear manufacturing processes
Material selection for high-performance gears
Experience with 3D CAD (NX / Creo / SolidWorks)
Hands-on experience with KISSsoft / KISSsys Preferred (Robotics Advantage)
Experience in compact gearbox design
Exposure to servo motor integration
Knowledge of backlash reduction techniques
Understanding of precision assembly & tolerance stack-up
Experience in lightweight material design Key Competencies
Strong analytical and problem-solving skills
Ability to translate heavy-duty gearbox principles into precision robotic actuators
Leadership and cross-functional coordination
Solid design validation and manufacturing support capability
📌 Lead Design Engineer (Vapi)
🏢 Meril
📍 Vapi
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