Mechanical Design Engineer: Robotics Hardware Engineering, Robot Design

**Summary:** At Meta, we're building the future of human connection and the technology that enables it. This means continuously inventing and developing technologies for the next generation of experiences.To continue our efforts in the path to AGI, and as we move closer to a future with intelligent robots and advanced AI models, we're hiring talent across a broad range of disciplines from robotics hardware to system software, machine perception, and artificial intelligence. These crucial projects and initiatives taken on by this team have never been done before, so you have a rare opportunity to help us create new ways people connect around the world.The Meta Robotics Hardware team is seeking a Mechanical Design Engineer focused on Robot Design with expertise in both advanced complex surface modeling and design for safety to exist between mechanical and industrial design teams. You will own the mechanical design of structural components, impact-attenuating structures, and human-contact surfaces — ensuring every external element of the product is both aesthetically refined and engineered to protect people during interaction. This role requires someone equally comfortable running crush-force calculations and building Class-A surfacing in CAD. This role will be part of a ME team responsible for concept development, analytical modeling, prototype design, first article build, fabrication, vendor management, and testing. Candidates should be comfortable working in a high ambiguity, fast paced environment where full system requirements are seldom known. This team is dedicated to building hardware that enables learning through data collection and system testing. **Required Skills:** Mechanical Design Engineer: Robotics Hardware Engineering, Robot Design Responsibilities: 1. Translate industrial design intent (from ID models, renderings, and printed busts) into CAD geometry with complex, multi-patch surface construction 2. Build and maintain Class-A and high-quality B-surface models for exterior robot panels, covers, and housings using advanced surfacing techniques (G2/G3 continuity, multi-span lofts, curvature-matched blends) 3. Manage the tension between aesthetic design intent, safety, structural, thermal, and manufacturing feasibility — negotiate changes that satisfy all three 4. Develop parametric surfacing strategies that allow rapid iteration on form while preserving engineering constraints (wall thickness, draft, undercut limits, parting lines) 5. Define and enforce safe-by-design guidelines: minimum edge radii, maximum surface hardness, breakaway/compliant panel strategies, and finger/limb entrapment gap standards 6. Design protective structures that limit contact force and pressure to safe thresholds during intended and unintended human-robot interaction 7. Own the mechanical safety architecture of the humanoid platform — exterior shells, padding systems, compliant covers, pinch-point elimination, and edge-radius standards 8. Conduct and maintain risk assessments (per ISO 10218, ISO/TS 15066, and emerging collaborative/humanoid robot safety standards) to identify hazards from moving parts, contact forces, and entrapment geometries 9. Perform hand calculations and FEA for impact, crush, and pinch scenarios 10. define material and geometry requirements that bound contact forces within safety limits 11. Collaborate with controls and firmware teams to ensure mechanical safety features complement electronic safety systems (force limiting, collision detection, safe stop) 12. Support safety certification efforts — prepare design evidence packages, test plans, and compliance documentation for regulatory submissions 13. Investigate and resolve safety-related findings from testing, user studies, and hazard reviews 14. Define and enforce surface quality standards: curvature continuity specs, reflection line criteria, and acceptable deviation from design intent 15. Work closely with DFMA engineers and molding vendors to ensure complex surfaces are manufacturable via injection molding, thermoforming, or composite layup — resolving draft, undercut, and flow challenges 16. Generate and manage scan-to-CAD workflows when iterating from physical models or prototypes 17. Produce rendered visualizations and surface analysis outputs (zebra stripes, curvature combs, deviation maps) to communicate design quality to stakeholders 18. Partner with industrial designers to jointly develop forms that are safe, beautiful, and buildable 19. Collaborate with mechanical design engineers on structural integration — mounting, sealing, cable routing, and serviceability behind exterior panels 20. Work with materials engineers on surface material selection: soft-touch elastomers, impact-absorbing foams, rigid plastics, and fabric/textile outers 21. Support user research and human factors teams with physical mock-ups and rapid prototypes for ergonomic and safety validation **Minimum Qualifications:** Minimum Qualifications: 22. BS degree in Mechanical Engineering or relevant field 23. 8+ years of mechanical design experience with significant work in complex surface modeling 24. Strong CAD proficiency (SolidWorks, NX, or CREO, Rhino) 25. Working knowledge of CNC machining processes — understanding of fixturing, tool access, setup minimization, and achievable tolerances 26. Experience with rapid prototyping manufacturing processes and materials 27. Experience designing exterior enclosures or covers for electromechanical products with high aesthetic standards 28. Working knowledge of mechanical safety principles — contact force limits, entrapment hazards, edge/radius requirements, and energy-absorbing material systems 29. Familiarity with injection molding, thermoforming, or composite manufacturing as it relates to complex-geometry parts 30. Ability to interpret and apply GD&T for sculptural parts with compound curvature 31. Strong collaboration skills — comfortable working at the intersection of industrial design, mechanical engineering, and safety 32. Experience managing time-sensitive projects through to completion while balancing evolving priorities and a broad range of stakeholders 33. Experience in tolerance analysis, geometric dimensioning and tolerancing (GD&T per ASME Y14.5) 34. Experience in Finite Element Analysis (FEA) 35. Strong communication skills with the ability to influence design decisions across multidisciplinary teams 36. Background in high-mix/low-volume transitioning to mid-volume production environments **Preferred Qualifications:** Preferred Qualifications: 37. Direct experience with robotic systems — BLDC motors, actuators, gearboxes, linkage mechanisms 38. MS in Mechanical Engineering, Product Design Engineering, or related discipline 39. Background in impact biomechanics or human injury tolerance thresholds (e.g., pain onset, bruising limits per ISO/TS 15066 body model) 40. Experience with Autodesk Alias or ICEM Surf for Class-A surface development 41. Familiarity with soft robotics materials — silicone skins, TPU, EVA foams, viscoelastic padding 42. Experience with physical prototyping methods for form validation: CNC foam milling, 3D printing, vacuum forming 43. Background in consumer electronics, automotive interiors, medical devices, or wearables where safety and surface quality are co-equal requirements 44. Knowledge of FEA for non-linear contact and soft material deformation (Abaqus, LS-DYNA, or similar) 45. Experience in thermal management 46. Familiarity with statistical tolerance analysis and process capability (Cp/Cpk) 47. Experience with additional manufacturing processes: sheet metal, additive manufacturing, anodizing, and plating 48. Experience with PLM/PDM systems (Teamcenter, Solidworks PDM, Windchill, or similar) 49. Experience writing a clear failure report that a cross-functional team can act on **Public Compensation:** $173,000/year to $245,000/year + bonus + equity + benefits **Industry:** Internet **Equal Opportunity:** Meta is proud to be an Equal Employment Opportunity and Affirmative Action employer. We do not discriminate based upon race, religion, color, national origin, sex (including pregnancy, childbirth, or related medical conditions), sexual orientation, gender, gender identity, gender expression, transgender status, sexual stereotypes, age, status as a protected veteran, status as an individual with a disability, or other applicable legally protected characteristics. We also consider qualified applicants with criminal histories, consistent with applicable federal, state and local law. Meta participates in the E-Verify program in certain locations, as required by law. Please note that Meta may leverage artificial intelligence and machine learning technologies in connection with applications for employment. Meta is committed to providing reasonable accommodations for candidates with disabilities in our recruiting process. If you need any assistance or accommodations due to a disability, please let us know at accommodations-ext@meta.com.