Mechanical Engineer, Robotics Hardware

About the role

Field AI is transforming how robots interact with the real world. We are building risk-aware, reliable, and field-ready AI systems that address the most complex challenges in robotics, unlocking the full potential of embodied intelligence. We go beyond typical data-driven approaches or pure transformer-based architectures, and are charting a new course, with already-globally-deployed solutions delivering real-world results and rapidly improving models through real-field applications. You will own the design and validation of mechanical systems that house and protect critical sensing and compute payloads for demanding field deployments. This role requires you to take ownership of the full mechanical lifecycle from initial concept through production support in challenging environments. You will be responsible for ensuring mechanical robustness, thermal performance, and manufacturability while adhering to strict mass and volume constraints. Collaboration with electrical, compute, and systems engineers is central to delivering integrated solutions that function reliably in the field. Additionally, you will contribute across all hardware domains beyond your primary mechanical focus to support the team's operational needs.

Key facts

What you'll do

• Conduct structural analysis and design mechanical frameworks for external enclosures, internal compute frames, and load-bearing chassis to withstand demanding operational conditions.
• Engineer robust sensor mounts and payload attachment points, defining mechanical interfaces that ensure stability and precise alignment in dynamic environments.
• Implement ingress protection strategies using gaskets, seals, membranes, and coatings to achieve and validate IP-rated enclosures against water and dust intrusion.
• Develop thermal management solutions incorporating fans, heat sinks, conductive paths, and airflow guides to maintain optimal operating temperatures for sensitive electronics.
• Adhere to mass and volume budgets by performing detailed trade studies to optimize payload constraints within strict volumetric envelopes and weight limitations.
• Build detailed SolidWorks CAD assemblies and perform FEA and thermal simulations to validate structural integrity, durability, and heat dissipation characteristics.
• Select materials and components based on mass, strength, thermal performance, and manufacturability requirements to meet system-level objectives.
• Apply Design for Manufacturing principles, ensuring designs are practical for CNC machining, sheet metal fabrication, additive manufacturing, and efficient assembly.
• Execute mechanical system testing including shock, vibration, thermal validation, ingress certification, and sensor alignment assessments to verify field readiness.
• Rapidly iterate on prototypes to resolve fit issues, evaluate thermal performance, and test integration with compute and sensing platforms in realistic scenarios.
• Produce mechanical drawings, GD&T annotations, Bills of Materials, and assembly instructions to support fabrication, QA processes, and field servicing.
• Manage weight, volume, and thermal budgets throughout the project lifecycle to ensure compliance with system-level requirements and operational goals.
• Work with vendors and contract manufacturers to procure mechanical hardware and develop QA checks for incoming production units.
• Investigate mechanical failures, deformations, and environmental weaknesses during testing and field deployments to drive corrective actions.
• Establish protocols for monitoring system mechanical health and loads to enable proactive maintenance and reliability improvements.

Requirements

• Currently pursuing a Bachelor of Science, Master of Science, or Ph.D. in Robotics, Mechanical Engineering, Mechatronics, or a closely related technical field.
• Demonstrate proficiency with SolidWorks or an equivalent mechanical CAD platform for complex system design and documentation.
• Apply finite element analysis and thermal modeling tools to evaluate mechanical performance and environmental resilience.
• Design hardware systems that survive vibration, shock, thermal cycling, and environmental exposure encountered in real-world operations.
• Utilize manufacturing processes such as CNC machining, sheet metal forming, additive manufacturing, and manual assembly in your design approach.
• Collaborate effectively with electrical, compute, and systems engineering teams to integrate mechanical components with sensors, power systems, and computing hardware.
• Exhibit comfort with mechanical debugging, thermal test setup, vibration testing equipment, and ingress testing methodologies.
• Extend capabilities to include electrical, sensing, and embedded computing tasks to deliver fully integrated robotic systems.

Nice to have

• Experience with field-deployed robotic systems where real-world environmental challenges directly influenced design decisions.

Practical notes

• Internship position based in Irvine, California.
• This role involves hands-on work with hardware systems and may include travel to field test sites as required.
• Candidates must be authorized to work in the United States without sponsorship for this internship role.