Senior Mechanical Design Engineer 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.

Main 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.
• Select materials and manufacturing processes that balance strength, weight, cost, and scalability to ensure both prototype feasibility and production readiness.
• 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.

Challenges

• Balancing Performance vs. Constraints: Managing trade-offs between strength, low weight, energy efficiency, reliability, and thermal management in a compact form factor, including designing custom high-precision actuation systems.
• Cross-Functional Integration and Interfacing: Ensuring seamless, rigorous integration of complex mechanical, electrical, and software subsystems, optimizing for cabling, sensors, and motor control.
• Scalability and Production Transition: Moving designs rapidly from custom prototypes to a robust, cost-effective, and scalable manufacturing process to support volume production growth.
• Fast-Paced, Multi-Disciplinary Environment: Thriving in a lean, fast-moving company, requiring the ability to own projects end-to-end, rapidly iterate, and adapt to evolving processes and tight deadlines.
• Adherence to Safety and Regulatory Standards: Implementing robust risk assessments and built-in safeguards from the initial design phase to ensure dynamic robotic systems meet international safety standards.

Qualifications, Knowledge, Key Skills and Experience

Essential

• 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.
• Experience performing FEA and structural validation for dynamic loading conditions.
• Hands-on prototyping experience.
• 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.
• Proven ability to take hardware from concept through validation and into production.

Desirable

• Direct experience developing legged or humanoid robotic systems.
• Experience designing custom actuators, gear trains (harmonic drives, cycloidal reducers, planetary systems), or high-precision joints.
• Knowledge of thermal management for compact electromechanical assemblies.
• Familiarity with motion control systems and basic control theory.
• Understanding of safety standards for robotic systems.
• Startup experience or experience in fast-paced hardware development environments.
• Experience transitioning from prototype to volume manufacturing.
• Experience with mesh organic mesh modelling (Blender, Z-Brush).

About Engineered Arts

Engineered Arts is the leading manufacturer of full-size humanoid robots used for entertainment, education and communication. 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. Our Ameca robot is well known as ‘the face of AI’ and a social media viral success, taking advantage of the generative AI craze. Along with our ultra-realistic Mesmer range of animated figures our robots continue to surprise and excite visitors at museums, theme parks, visitor attractions and trade shows as well as aid leading universities with AI and robotics research. Our robots are poised to break into the future mega-expansion service robot segment, with applications such as front of house, receptions, check-in desks, information points and PoS. We are a team of dedicated engineers and creatives striving to develop the very best experiences for our customers. Our internal motto is ‘Be Wow’, everything we do is fun, entertaining or surprising to encounter. We always push the boundaries of what is possible in humanoid robotics, researching and developing new systems and techniques to further their appeal. We explore and challenge the human perception of robots as well as the fear and discomfort and the excitement and joy life-like mechanical humanoids present.