Feeny
Physical Intelligence

Mechanical Design Engineer at Physical Intelligence (San Francisco, CA)

Physical Intelligence· San Francisco, CA·

Role details

Work type
Onsite
Employment
Full-Time
Skills
3D CAD2D drawingsMaterial selectionManufacturing processesInjection moldingDie castingStampingMachiningBonding methodsFEA toolsHALT/HASSFMEA

Summary

Drive the integration and development of robotic systems by owning the full mechanical development spectrum from concept to deployment. The role involves leading innovative designs, optimizing manufacturing processes, ensuring reliability, and collaborating with cross-functional teams to produce high-volume producti...

Job description

We're looking for an experienced mechanical engineer to drive the integration and development of our robotic systems, leading innovative designs from concept to deployment. You'll own the full spectrum of mechanical development—from actuator sizing or design to kinematics and work with teams to prototype and ultimately produce systems at scale—ensuring reliability, deployability, and performance. The ideal candidate is a hands-on innovator with deep expertise in mechatronic systems, combining theoretical knowledge with practical engineering skills. Experience with actuation systems, electromechanical integration, machine design, and a track record of bringing mechanical systems to life is essential. If this sounds like you, please apply!

In This Role You Will

  • Own the mechanical design lifecycle: Drive all design decisions around 3D CAD, 2D drawings, material selection, and manufacturability — from early concept and proof-of-concept prototypes through high-volume production.
  • Develop and refine manufacturing processes: Identify and optimize injection molding, die casting, stamping, machining, adhesives, and bonding methods for new and existing products.
  • Ensure reliability and robustness: Perform and interpret reliability tests (HALT/HASS, tolerance stack-ups, environmental testing) and lead corrective design actions.
  • Leverage simulation for smart decisions: Use basic FEA tools (thermal, structural, vibrational) and first-order analyses to validate or guide design from early phases onward.
  • Lead system integration efforts: Collaborate with electrical and radio teams to balance thermal, EMI, mechanical stability, and accessibility needs in tightly integrated assemblies.
  • Prototype and iterate quickly: Build proof-of-concept designs, run experiments, and translate findings into high-yield, mass-production-ready solutions.
  • Manage vendor relationships: Evaluate DFM, cost, yield, and timeline trade-offs; work with JDM/CM/ODM partners; own and drive supplier selection where needed.
  • Communicate effectively across teams: Conduct design reviews with cross-functional stakeholders, clearly articulating design rationale, risks, and trade-offs.

What We Hope You'll Bring

  • 7+ years of experience taking hardware products from concept to production, with a strong portfolio of shipped mechanical designs — preferably in robotics, automotive, or consumer products
  • Bachelor's Degree in Mechanical or Aerospace Engineering, or equivalent experience
  • Deep understanding of high-volume manufacturing processes (injection molding, die casting, stamping, machining, bonding)
  • Familiarity with HALT/HASS, FMEA, DOE methodologies, and test-to-failure approaches for robust mechanical design
  • Practical understanding of when and how to apply FEA tools, with the ability to make first-order engineering judgments
  • Proven record of mechanically integrating electronics (sensors, PCBs, antennas, batteries) in complex assemblies
  • Ability to lead reviews, influence cross-functional teams, and convey risks and solutions clearly
  • Comfort in early-stage, resource-limited startup environments with a willingness to move quickly and hands-on
  • Proficiency in prototyping methods including machining (mill, lathe), sheet metal fabrication, 3D printing, and injection molding
  • Experience building and testing prototypes and analyzing failures to implement improvements

Pursuant to the San Francisco Fair Chance Ordinance, we will consider for employment qualified applicants with arrest and conviction records.

Why work at Physical Intelligence

  • Culture: Described as a “pure company” – internally driven by research needs, not external market demands. Highly collaborative, with a mix of engineers, scientists, and roboticists working together.
  • Work Environment: Hybrid/in-office – most roles require on-site presence in San Francisco (396 Treat Ave), though some remote flexibility exists. In-office setting with a “no reception” vibe, open lab space with robot stations.
  • Growth: Team has scaled from ~80 (Jan 2026) to 163 (mid-2026) and is still hiring across research, ML infra, hardware, and engineering roles. Plans to grow “as slowly as possible” to maintain quality.
  • Perks & Engineering Highlights: Access to cutting-edge robotics hardware and compute resources; opportunity to publish research and open-source code; exposure to a wide variety of real-world automation challenges (e.g., robots learning to fold pants, peel vegetables, make espresso). Employees come from top institutions like Berkeley, Stanford, Google, NVIDIA, and Anduril.

Application questions