Apprentice Prototype Build Engineer Jobs in Chicago, IL

About the role

We're partnering with a well-funded robotics startup building an integrated hardware and software platform for embodied AI. The team is developing a new generation of advanced robots alongside the software stack that runs them, with the goal of making robots far easier to build, program, and deploy. This is an early, high-ownership environment where your designs ship on every unit that leaves the factory.

We're looking for a Senior Mechanical Engineer to design, test, and implement key hardware components for an advanced humanoid robot platform. You will own mechanical subsystems end to end, from requirements definition through 3D CAD, prototype build, supplier qualification, first-article inspection, and production release.

This is a hands-on role spanning the full development arc, from first prototype on the bench to production-ready design at a contract manufacturer. You will own that transition: designing for manufacturability from day one, driving DFM reviews, resolving first-article failures, and making sure your designs survive the gap between "works in the lab" and "ships at volume." You'll work alongside electrical, firmware, and controls engineers daily.

Responsibilities

• Design parts and assemblies in 3D CAD that satisfy load conditions, form factor constraints, range-of-motion requirements, and durability targets
• Determine component-level mechanical requirements (stiffness, strength, fatigue, thermal) from system-level functional specs
• Apply analytical methods (FEA, tolerance stack-up, kinematic analysis) before releasing designs for prototyping or production
• Generate accurate 2D drawings with GD&T per ASME Y14.5 appropriate for both prototype and production inspection methods
• Build prototypes to test assembly, range of motion, wire routing, and integration with adjacent subsystems
• Design and build test stands and fixtures; conduct structured validation testing and document results rigorously
• Own the prototype-to-production transition for your subsystems: apply DFM/DFA principles from the first design iteration, not as a final step; drive the design changes required to hit manufacturability, yield, and cost targets
• Work with suppliers to select and qualify parts; inspect first articles, perform root cause analysis on failures, and drive corrective action to closure
• Conduct DFM/DFA reviews with contract manufacturers; define and own mechanical acceptance criteria, support tooling bring-up, and stay engaged through production ramp
• Define and execute structured validation plans, including environmental, fatigue, and functional testing, to prove out designs before they lock for production
• Collaborate closely with electrical engineers on electromechanical integration: motor mounting, sensor placement, wire harness routing, connector access
• Contribute to materials selection, surface finishing, and manufacturing process decisions across the robot

Minimum qualifications

• 5+ years of mechanical engineering experience in robotics, industrial automation, automotive, aerospace, or consumer electronics, with at least one product shipped to production
• Expert proficiency in 3D CAD (SolidWorks, NX, CATIA, Onshape, or equivalent) for complex parts and assemblies with tight tolerances
• Mastery of GD&T per ASME Y14.5 and the ability to create production-ready 2D drawings
• Experience with actuators and transmission systems: strain-wave (harmonic), planetary, cycloidal gearing, or direct-drive
• Hands-on experience with structural analysis (FEA) and tolerance stack-up analysis as part of routine design validation
• Proven electromechanical integration experience: motors, sensors, encoders, wire harnesses, and connectors in tight mechanical envelopes
• Demonstrated ability to take a mechanical design from working prototype to production-ready, including DFM iterations, supplier qualification, first-article inspection, and manufacturing yield validation.
• Candidates who have only worked in R&D or prototype-only environments are not a fit for this role

Preferred qualifications

• Deep familiarity with modern manufacturing processes and when to apply each: CNC machining (3- and 5-axis), injection molding, die casting, sheet metal fabrication, MIM, investment casting, and surface finishing (anodizing, PVD, powder coat); understanding of tradeoffs across cost, tolerance, lead time, and volume
• Direct experience working with contract manufacturers: DFM reviews, tooling bring-up, first-article inspection, and yield improvement
• Hands-on prototyping with rapid fabrication methods (FDM/SLA/SLS 3D printing, CNC soft tooling, urethane casting) and inspection equipment including CMM, optical comparators, and CT scanning for first-article validation
• Experience with thermal design and heat dissipation in compact electromechanical systems
• Background in reliability engineering: fatigue analysis, HALT/HASS, or accelerated life testing
• Wire harness design experience
• Proficiency with simulation tools beyond FEA: CFD, multi-body dynamics (Adams, Simscape), or kinematic simulation
• Familiarity with functional safety requirements for mechanisms operating near humans