Mechanical Design Engineer, Cad, Solidworks in Cornwall, Falmouth

We are looking for a Mechanical Engineer to join a small, highly skilled team building advanced humanoid robotic platforms capable of dynamic, real-world operation. You will design and integrate complex mechanical subsystems - including actuation, structural frames, transmission systems, and thermal solutions. The ideal candidate thrives in fast-paced hardware development environments and has demonstrated success delivering high-performance electromechanical systems from prototype to scalable production.

Key Responsibilities:

• Design and develop mechanical components and subsystems for humanoid robots, including structural frames, precision joints, and actuator assemblies, using advanced CAD tools and rigorous GD&T practices.
• Engineer high-performance robotic linkages and transmission mechanisms optimized for dynamic motion, load handling, durability, and energy efficiency.
• Collaborate with in-house manufacturing team for rapid prototyping efforts using additive manufacturing, CNC machining, and iterative hardware testing to validate and refine designs.
• Collaborate closely with electrical and software engineering teams to integrate mechanical systems with sensing, control, and embedded hardware architectures.
• Conduct mechanical analysis and validation testing (e.g., FEA, fatigue, impact, and life-cycle testing) to verify performance under real-world operating conditions.
• Drive safety-by-design principles, performing risk assessments and implementing safeguards to meet applicable regulatory and operational safety standards.
• Generate and maintain detailed engineering documentation, including production drawings, tolerance analyses, specifications, and bills of materials.
• Contribute to system-level design reviews and cross-functional execution to ensure on-time, high-quality hardware delivery.

Qualifications:

• Strong background in mechanical design, statics, dynamics, and material science.
• Advanced proficiency in 3D parametric CAD (preferably Autodesk Inventor).
• Deep understanding of GD&T and tolerance stack-up analysis.
• Strong background in mechanism design, linkages, bearings, power transmission, and actuator integration.
• Knowledge of material selection for lightweight, high-strength structures (aluminum alloys, steels, composites).
• Experience designing for manufacturability (DFM) and assembly (DFA).
• Ability to work cross-functionally with electrical and controls teams to integrate motors, sensors, wiring, and embedded systems.
• Direct experience developing legged or humanoid robotic systems.
• Knowledge of thermal management for compact electromechanical assemblies.
• Understanding of safety standards for robotic systems.

With 20 years of hardware and software development, our robots have been sold in over 30 countries worldwide with customers such as NASA, PwC, Meta and many more. We are a team of dedicated engineers and creatives striving to develop the very best experiences for our customers. We always push the boundaries of what is possible in humanoid robotics, researching and developing new systems and techniques to further their appeal.