Lead Design Engineer

Meril · India

Job Description

Lead Design Engineer – Actuator Manufacturing

Location: Vapi

Position Overview

We are seeking a highly experienced Lead Design Engineer to lead the design and manufacturing development of precision actuators for robotic systems. The ideal candidate will have strong expertise in gearbox design, transmission systems, gear calculations, and manufacturing process planning, with the ability to translate heavy-duty gearbox knowledge into compact, high-precision robotic actuator systems.

This role will focus on developing high-torque-density, lightweight, and precision transmission systems used in robotic joints such as hip, knee, shoulder, and elbow assemblies.

Why Gearbox Experience is Critical for Robotics Actuators?

Your gearbox experience directly contributes to:

• Planetary gear reduction system design
• Shaft and bearing life calculations
• Gear rating and safety validation (AGMA / ISO standards)
• Manufacturing stage drawing & process planning
• Precision assembly support

Key Responsibilities

1. Actuator Transmission Design

• Lead design of precision planetary and harmonic-like gear reduction systems for robotic actuators.
• Develop compact, lightweight transmission systems for humanoid robot joints.
• Perform torque density optimization and reduction ratio selection.
• Design shafts, gears, bearings, and housing for high accuracy applications.

2. Engineering Calculations & Validation

• Perform:
• Gear rating calculations
• Shaft safety analysis
• Bearing life estimation
• Torsional stiffness analysis
• Use KISSsoft / KISSsys for gear system validation.
• Optimize backlash and precision performance.
• Ensure compliance with ISO / AGMA standards.

3. Manufacturing Development

• Develop gear manufacturing process plans for precision gears.
• Design jigs & fixtures for actuator assembly.
• Support precision machining and heat treatment processes.
• Ensure tolerance stack-up analysis for high-accuracy systems.

4. Prototype & Testing Support

• Support actuator prototype builds.
• Work closely with motor integration team.
• Troubleshoot assembly and performance issues.
• Improve efficiency, noise reduction, and vibration control.

5. PLM, Documentation & Systems

• Create GA, sectional, and detailed manufacturing drawings.
• Manage BOM using PLM/PDM systems (Teamcenter / Windchill / EPDM).
• Coordinate ERP integration with SAP / Oracle.

6. Cross-Functional Leadership

• Collaborate with:
• Motor design team
• Electronics team
• Control systems team
• Manufacturing team
• Guide and mentor junior engineers.
• Lead design reviews and technical validation sessions.

Required Qualifications

• B.E. Mechanical Engineering
• 10+ years experience in gearbox / transmission design
• Strong knowledge of:
• Planetary gear systems
• Shaft & bearing calculations
• Gear manufacturing processes
• Material selection for high-performance gears
• Experience with 3D CAD (NX / Creo / SolidWorks)
• Hands-on experience with KISSsoft / KISSsys

Preferred (Robotics Advantage)

• Experience in compact gearbox design
• Exposure to servo motor integration
• Knowledge of backlash reduction techniques
• Understanding of precision assembly & tolerance stack-up
• Experience in lightweight material design

Key Competencies

• Strong analytical and problem-solving skills
• Ability to translate heavy-duty gearbox principles into precision robotic actuators
• Leadership and cross-functional coordination
• Strong design validation and manufacturing support capability