Sr Mechanical Engineer, Fan and Duct Design

Figure is an AI robotics company developing autonomous general-purpose humanoid robots. The goal of the company is to ship humanoid robots with human level intelligence. Its robots are engineered to perform a variety of tasks in the home and commercial markets. Figure is headquartered in San Jose, CA. We are seeking a Senior Mechanical Engineer focused on Fan and Duct Design to own the end-to-end development of the robot’s airflow systems from early impeller geometry prototypes to production-ready assemblies released to manufacturing. Responsibilities: Own the mechanical design of the robot’s fan assemblies: impellers, housings, ducts, diffusers, seals, shrouds, baffles, and mounting structures. Translate CFD-engineered impeller geometry into fully detailed, moldable components with proper drafts, ribs, gates, cooling channels, and tooling strategies. Develop manufacturable plastic parts (injection-molded), metal components, and hybrid structures for quiet, efficient airflow. Select, qualify, and integrate fan motors including BLDC, slotless motors, PMSMs, or custom motor architectures depending on system targets. Collaborate with motor vendors and CMs to determine winding specs, bearings, back-EMF constants, and long-life design constraints with additional support from the Figure motor team Support thermal and acoustic engineers by designing test fixtures, running airflow tests, and validating fan performance. Own iterative cycles: prototype → measure → redesign → retest. Drive supplier engagement on tooling, gating, draft strategies, warpage control, and tolerance analyses. Partner with GSM and CMs to close out DFM, tooling release, mold trials, and FAIs. Create drawing packages, GD&T, BOMs, and assembly instructions for production. Collaborate with CFD, thermal, acoustics, system architecture, IDand manufacturing teams to converge on a highly optimized fan system. Work with global suppliers to evaluate materials, molding processes, motor options, and assembly methods. Provide hands-on build support for engineering units and early factory runs. Requirements: 5+ years experience in mechanical engineering, electromechanical design, turbomachinery components, or similar. Bachelor’s or Master’s in Mechanical Engineering, Mechatronics, Aerospace, or related field. Expert in 3D CAD modeling and surfacing; comfort with complex geometries derived from CFD. Deep understanding of mechanical design for airflow systems: fans, ducts, impellers, shrouds, or related components. Experience turning CFD geometry into manufacturable CAD suitable for tooling. Familiar with experimental methods for measuring flow, pressure, and acoustic performance. Strong DFM knowledge for injection molding, tooling, and assembly. Ability to write clear documentation, test plans, and release packages. Bonus Qualifications: Experience with small BLDC fan motors, custom motor sourcing, or electromechanical integration. Background in acoustics, noise reduction, vibration isolation, or fan blade noise characterization. Experience with high-volume plastic injection molding and tool releases. CATIA V6 experience. The US base salary range for this full-time position is between $160,000 - $200,000 annually. The pay offered for this position may vary based on several individual factors, including job-related knowledge, skills, and experience. The total compensation package may also include additional components/benefits depending on the specific role. This information will be shared if an employment offer is extended.