Actuator Gear Design Engineer

About the role

The Robotics team at OpenAI is dedicated to unlocking general-purpose robotics and advancing toward AGI-level intelligence within dynamic, real-world environments. This role owns the complete actuator development lifecycle, from early concept generation and system-level architecture to prototype validation and seamless integration into broader robotic platforms. The hire will establish and refine scalable design, test, and integration practices that future robotic systems can leverage for performance and reliability. You will operate at the intersection of electromechanical design and high-level AI, ensuring physical constraints are respected while maximizing capabilities. Success in this position requires close collaboration with mechanical, electrical, controls, firmware, and reliability teams to align hardware with system goals. You will also engage with external suppliers and internal manufacturing partners to transform designs into robust, production-ready gearbox assemblies. This position is based in San Francisco, CA, and requires in-person presence four days per week to foster deep collaboration and rapid iteration.

What you'll do

• Lead the architecture, design, and integration of custom robotic actuator gearing across multiple form factors and performance targets.
• Define actuator requirements and execute system-level trade studies that balance torque density, bandwidth, efficiency, thermal performance, back drivability, inertia, reliability, manufacturability, and cost.
• Design precision electromechanical assemblies with rigorous attention to tolerances, alignment, load paths, thermal expansion, sealing, wear, and long-term serviceability.
• Drive actuator integration into robotic systems, partnering closely with controls, firmware, electrical, and software teams to optimize closed-loop performance and responsiveness.
• Develop and evaluate architectures that incorporate integrated sensing and encoder strategies to meet accuracy, stability, and diagnostic needs.
• Build and validate prototypes through hands-on bring-up, debugging, instrumentation, characterization, and iterative refinement based on empirical data.
• Create test methodologies and characterization infrastructure for evaluating actuator performance, reliability, durability, and failure modes under varied conditions.
• Analyze test data to identify root causes of limitations and failure modes, and translate findings into concrete design improvements.
• Collaborate with manufacturing and supplier partners to transition designs from low-volume prototypes to scalable, production-ready assemblies without compromising performance.
• Support DFM, DFA, DFT, calibration, and assembly strategies specific to electromechanical subsystems to streamline production and reduce complexity.
• Contribute to actuator sourcing strategy, vendor qualification processes, prototype builds, and the development of a resilient supply chain.
• Document designs, interfaces, validation results, and engineering decisions in detail to support long-term maintainability, reproducibility, and production readiness.
• Help establish engineering standards, integration practices, and development workflows that can be reused across future robotic platforms and product lines.

Requirements

• Hold a Bachelor's degree in Mechanical Engineering, Robotics, Mechatronics, or a closely related technical field as a baseline for advanced engineering responsibilities.
• Demonstrate 5+ years of professional experience designing gear systems, robotic actuators, or precision mechatronic hardware for demanding applications.
• Bring deep experience developing transmission elements for robotics, automation, aerospace, automotive, or other high-performance dynamic systems where reliability is critical.
• Show strong mastery of motors, transmissions, bearings, encoders, structural components, thermal management, and precision mechanical integration techniques.
• Prove capability in actuator sensing architectures, including encoder integration, calibration strategies, and signal processing for accurate feedback.
• Have hands-on experience designing for both prototype and production manufacturing processes, including machining, casting, molding, and complex assembly methods.
• Exhibit proficiency with engineering tools and methods relevant to modeling, simulation, and analysis of mechanical and electromechanical systems.
• Communicate effectively across multidisciplinary teams and collaborate seamlessly with research, controls, manufacturing, and operations professionals to align on objectives.

Nice to have

• Prior experience contributing to robotic hardware that has progressed from research experiments to fielded, production-scale systems.
• Familiarity with advanced manufacturing techniques and materials used in high-volume robotics production.
• Exposure to safety-critical systems where failure modes must be rigorously analyzed and mitigated through design.

Practical notes

This role requires in-person presence in San Francisco, CA, four days per week to enable close collaboration, rapid prototyping, and alignment with team schedules. The position is full-time with standard working hours as determined by team norms and project needs. No external visa sponsorship details, travel requirements, or specific application deadlines are published at this time.