Mechanical Design Engineer: Robotics Hardware Engineering, DFMA

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 with a extensive experience in Design for Manufacturing and Assembly (DFMA). In this role, you will ensure that complex electromechanical systems — actuators, structural components, integrated sensor packages, and cladding — are designed from the ground up for efficient, repeatable, and future-scalable production. You'll work at the intersection of robot design, materials science, and manufacturing engineering to bring novel platforms from prototype to low volume production. 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.

Responsibilities
Drive DFMA principles across the full mechanical design lifecycle of robot platforms— from concept through low-volume production
* Explore and prototype alternate manufacturing methods/processes (investment casting, die casting, molding, additive) as alternative for machining for larger structural components
* Work directly with design engineers to simplify part geometry, reduce fastener count, consolidate components, and minimize assembly steps without compromising performance
* Develop and maintain design guidelines, tolerance stacks, and assembly specifications tailored to robotic systems (actuators, linkages, structural chassis, cable routing, skin/shell enclosures)
* Perform manufacturing feasibility assessments on new designs; identify risk areas and propose design changes early in the development cycle
* Lead DFM reviews with internal teams and external manufacturing partners (CNC, sheet metal, injection molding, die casting, additive manufacturing)
* Define and optimize assembly sequences, fixturing strategies, and joining methods (threaded fasteners, adhesives, press fits, snap fits, welding)
* Create and maintain Bill of Materials (BOM) cost models; weight and cost reduction initiatives through material selection, process optimization, and part consolidation
* Collaborate closely with electrical, firmware, and controls engineers to ensure integrated system-level manufacturability
* Support supplier development — qualify processes, conduct site visits, and establish inspection criteria for critical-to-function features and interfaces
* Develop and document standard work instructions and assembly aids for prototype and production builds
* Collaboration: Work closely with a cross-functional team of engineers (EE, SW, Firmware) to deliver complete technical solutions
* Sustaining engineering: Troubleshooting root-cause of mechanical failures, implementing improved designs, testing effectiveness of change

Qualifications
7+ years experience in Mechanical Design Engineering with focused on DFMA
* BS degree in Mechanical Engineering
* Experience designing complex electro-mechanical, tightly integrated, and consumer level solutions
* Deep working knowledge and prior experience with component manufacturing processes: CNC machining, injection molding, die casting, sheet metal fabrication, and additive manufacturing
* Experience with SOLIDWORKS, Siemens NX or similar CAD tools
* Experience with rapid prototyping manufacturing processes and materials
* Experience managing time-sensitive projects through to completion while balancing evolving priorities and a broad range of stakeholders
* Experience in tolerance analysis, geometric dimensioning and tolerancing (GD&T per ASME Y14.5)
* Experience in Finite Element Analysis (FEA)
* Experience with tolerance analysis tools and methodologies (RSS, Monte Carlo, worst-case)
* Familiarity with common joining and fastening methods and their trade-offs in robotic assemblies
* Strong communication skills with the ability to influence design decisions across multidisciplinary teams
* Experience with lightweighting strategies (topology optimization, lattice structures, composite materials)
* Background in high-mix/low-volume transitioning to mid-volume production environments Experience with plastic injection molding
* Knowledge of reliability engineering concepts (FMEA, HALT/HASS, life testing) as they relate to mechanical design
* Direct experience with robotic systems — BLDC motors, actuators, gearboxes, linkage mechanisms
* Experience driving and leading projects from cradle to grave