About This Job

Meril

Location: Vapi, Gujarat, India

Work Mode: On-site

Industry: Robotics Engineering,Industrial Machinery Manufacturing,Automation Machinery Manufacturing

Lead Design Engineer – Actuator Manufacturing

Location: Vapi

Position Overview

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 solid 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 designShaft and bearing life calculationsGear rating and safety validation (AGMA / ISO standards)Manufacturing stage drawing & process planningPrecision assembly support

Key Responsibilities

- 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.

- Engineering Calculations & Validation





Perform:Gear rating calculationsShaft safety analysisBearing life estimationTorsional stiffness analysisUse KISSsoft / KISSsys for gear system validation.Optimize backlash and precision performance.Ensure compliance with ISO / AGMA standards.

- 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 teamElectronics teamControl systems teamManufacturing teamGuide and mentor junior engineers.Lead design reviews and technical validation sessions.

Required Qualifications

B.E.

Mechanical

Engineering10 years experience in gearbox / transmission designStrong knowledge of:Planetary gear systemsShaft & bearing calculationsGear manufacturing processesMaterial selection for high-performance gearsExperience with 3D CAD (NX / Creo / SolidWorks)Hands-on experience with KISSsoft / KISSsys

Preferred (Robotics Advantage)

Experience in compact gearbox designExposure to servo motor integrationKnowledge of backlash reduction techniquesUnderstanding of precision assembly & tolerance stack-upExperience in lightweight material design

Key Competencies

Strong analytical and problem-solving skillsAbility to translate heavy-duty gearbox principles into precision robotic actuatorsLeadership and cross-functional coordinationStrong design validation and manufacturing support capability

📌 Lead Design Engineer (Vapi)
🏢 Meril
📍 Vapi