Lead Robotics Actuator Engineer

Location: Downers Grove, IL

Job Type: Full-Time | On-Site

Position Overview: We are seeking an experienced Lead Robotics Actuator Engineer to lead the design, development, and production of advanced robotic servo actuators. The ideal candidate will have strong expertise in precision gearbox development, custom brushless motor design, and electromechanical systems, with experience taking products from concept through manufacturing.

Key Responsibilities: Lead the design and development of robotic actuators, including motors, gearboxes, bearings, shafts, and housings. Design and optimize precision planetary gearboxes and low-backlash gearing systems. Develop custom brushless motors, including stator/rotor geometry, winding specifications, and performance optimization. Perform engineering calculations for torque, speed, efficiency, thermal performance, gear strength, and reliability. Design mechanical components, rotating assemblies, bearing arrangements, and actuator housings. Integrate encoders, sensors, and feedback systems with mechanical and electrical components. Develop prototypes, conduct performance and reliability testing, and troubleshoot design issues. Work with suppliers and manufacturers on component specifications, quality, and production readiness. Prepare CAD models, engineering drawings, BOMs, and manufacturing documentation. Lead technical development activities from initial design through production.

Required Qualifications: 7+ years of experience in robotics, actuator development, precision gearboxes, electric motors, or electromechanical engineering. Proven experience designing custom gearboxes or geared actuators and taking them into manufacturing. Hands-on custom brushless motor design experience beyond selecting off-the-shelf motors. Strong knowledge of planetary gears, motor design, bearings, mechanical tolerances, and rotating assemblies. Proficiency in 3D CAD tools such as SolidWorks or Autodesk Fusion. Experience with engineering calculations, prototyping, testing, and failure analysis. Experience working directly with manufacturers and suppliers. Bachelor's degree in Mechanical Engineering, Electrical Engineering, Mechatronics, or a related field, or equivalent experience.

Preferred Qualifications: Experience with compact robotic joint actuators and low-backlash planetary gearboxes. Knowledge of precision gear manufacturing, heat treatment, and finishing processes. Experience with frameless or high-torque-density brushless motors. Familiarity with Ansys Maxwell, Motor-CAD, JMAG, KISSsoft, or Romax. Experience taking actuator designs from prototype to volume production.