Lead Design Engineer – Actuator Manufacturing

About the role

We are looking for a highly experienced Lead Design Engineer to head the design and manufacturing development of precision actuators used in robotic systems. The role focuses on creating compact, high‑torque‑density transmission solutions for humanoid robot joints such as hips, knees, shoulders and elbows.

Key responsibilities

• Lead the design of planetary and harmonic‑like gear reduction systems for robotic actuators.
• Perform gear rating, shaft safety, bearing life, and torsional stiffness calculations using KISSsoft/KISSsys.
• Develop manufacturing process plans, jigs, fixtures and support precision machining and heat‑treatment operations.
• Create detailed GA, sectional and manufacturing drawings and manage BOMs in PLM/PDM tools (Teamcenter, Windchill, EPDM).
• Coordinate ERP integration with SAP/Oracle and ensure tolerance stack‑up analysis for high‑accuracy assemblies.
• Support prototype builds, motor integration, and troubleshoot performance issues.
• Collaborate with motor, electronics, control‑systems and manufacturing teams while mentoring junior engineers.

Required profile

• B.E. Mechanical Engineering or equivalent.
• 10+ years of experience in gearbox or transmission design.
• Strong knowledge of planetary gear systems, shaft and bearing calculations, and gear manufacturing processes.
• Experience with material selection for high‑performance gears.
• Hands‑on experience with 3D CAD tools (NX, Creo, SolidWorks) and KISSsoft/KISSsys.
• Preferred: experience in compact gearbox design for robotics, servo‑motor integration, and backlash reduction techniques.

Required skills

• Gearbox and transmission design
• Planetary and harmonic gear systems
• Torque density optimization
• Gear rating and safety calculations
• Shaft and bearing analysis
• KISSsoft / KISSsys
• 3D CAD (NX, Creo, SolidWorks)
• PLM/PDM (Teamcenter, Windchill, EPDM)
• ERP integration (SAP, Oracle)
• Material selection for gears
• Manufacturing process planning
• Jig and fixture design
• Precision machining and heat‑treatment
• Tolerance stack‑up analysis