Sr Mechanical Engineer, Fan and Duct Design

Figure is an AI robotics company developing autonomous general-purpose humanoid robots. The goal of the company is to ship humanoid robots with human level intelligence. Its robots are engineered to perform a variety of tasks in the home and commercial markets. Figure is headquartered in San Jose, CA.

We are seeking a Senior Mechanical Engineer focused on Fan and Duct Design to own the end-to-end development of the robot’s airflow systems from early impeller geometry prototypes to production-ready assemblies released to manufacturing.

Responsibilities:

• Own the mechanical design of the robot’s fan assemblies: impellers, housings, ducts, diffusers, seals, shrouds, baffles, and mounting structures.
• Translate CFD-engineered impeller geometry into fully detailed, moldable components with proper drafts, ribs, gates, cooling channels, and tooling strategies.
• Develop manufacturable plastic parts (injection-molded), metal components, and hybrid structures for quiet, efficient airflow.
• Select, qualify, and integrate fan motors including BLDC, slotless motors, PMSMs, or custom motor architectures depending on system targets.
• Collaborate with motor vendors and CMs to determine winding specs, bearings, back-EMF constants, and long-life design constraints with additional support from the Figure motor team
• Support thermal and acoustic engineers by designing test fixtures, running airflow tests, and validating fan performance.
• Own iterative cycles: prototype → measure → redesign → retest.
• Drive supplier engagement on tooling, gating, draft strategies, warpage control, and tolerance analyses.
• Partner with GSM and CMs to close out DFM, tooling release, mold trials, and FAIs.
• Create drawing packages, GD&T, BOMs, and assembly instructions for production.
• Collaborate with CFD, thermal, acoustics, system architecture, IDand manufacturing teams to converge on a highly optimized fan system.
• Work with global suppliers to evaluate materials, molding processes, motor options, and assembly methods.
• Provide hands-on build support for engineering units and early factory runs.

Requirements:

• 5+ years experience in mechanical engineering, electromechanical design, turbomachinery components, or similar.
• Bachelor’s or Master’s in Mechanical Engineering, Mechatronics, Aerospace, or related field.
• Expert in 3D CAD modeling and surfacing; comfort with complex geometries derived from CFD.
• Deep understanding of mechanical design for airflow systems: fans, ducts, impellers, shrouds, or related components.
• Experience turning CFD geometry into manufacturable CAD suitable for tooling.
• Familiar with experimental methods for measuring flow, pressure, and acoustic performance.
• Strong DFM knowledge for injection molding, tooling, and assembly.
• Ability to write clear documentation, test plans, and release packages.

Bonus Qualifications:

• Experience with small BLDC fan motors, custom motor sourcing, or electromechanical integration.
• Background in acoustics, noise reduction, vibration isolation, or fan blade noise characterization.
• Experience with high-volume plastic injection molding and tool releases.
• CATIA V6 experience.

The US base salary range for this full-time position is between $160,000 - $200,000 annually.

The pay offered for this position may vary based on several individual factors, including job-related knowledge, skills, and experience. The total compensation package may also include additional components/benefits depending on the specific role. This information will be shared if an employment offer is extended.