Staff Actuator Design Engineer
Palo Alto$200k - $230kFull-timePosted 2w ago
About the role
ALSO is seeking a Staff Actuator Design Engineer to design electromechanical actuators that control critical functions of next-generation light electric vehicles, including braking and steering systems. The role spans from concept to production, acting as a subject matter expert on actuation across vehicle platforms.
Responsibilities
- Design, develop, and test electromechanical actuators and motor-driven mechanisms for light electric vehicle platforms
- Create detailed drawing packages and manufacturing instructions for mechanical parts and assemblies
- Perform 3D modeling of components and assemblies (die castings, injection-molded plastics, sheet metal, powder metal, MIM)
- Collaborate with electrical engineers to integrate PCBAs, wire harnesses, and electronic systems into mechanical designs
- Collaborate with controls engineers to ensure physical systems support robust control and seamless integration with embedded software
- Coordinate validation efforts with Tier 1 and Tier 2 suppliers
- Develop and execute design verification plans and reports (DVP&R)
- Lead and maintain design failure mode and effects analyses (DFMEAs)
- Prototype and iterate designs using hands-on fabrication and lab testing
- Set actuator design standards and best practices for the engineering team
- Mentor and develop engineers through design reviews, technical guidance, and hands-on collaboration
Qualifications
- BS/MS in Mechanical Engineering, Electrical Engineering, or related field
- 8+ years of experience designing electromechanical actuators
- Deep understanding of motors, servo drives, and motion sensors
- Design experience with precision motion mechanisms (force/displacement amplification, mechanical linkages, motion transmission systems: spur, planetary, worm, cycloidal gearing, lead screws, ball screws)
- Deep understanding of friction, damping, and backlash, and how to mitigate and control them
- Ability to model mechanical behavior (stiffness, losses, backlash) using MATLAB/Simulink, Amesim, or equivalent 1D multiphysics tool
- Strong foundation in material properties, coatings, heat treatment, statics, and dynamics
- Knowledge of control strategies and firmware implementation
- Proficient in 3D/2D CAD (Catia V5/V6 preferred) and CAE tools (Ansys, Abaqus, HyperWorks, or similar)
- Strong knowledge of GD&T and tolerance stack-up analysis
- Bonus: Proficient in developing low-level drivers using Python, C, and C++
- Bonus: Design experience with PCBA integration and wire harness design
- Bonus: Familiarity with PLM systems, BOM structuring, engineering changes, and deviation processes
Benefits
- Robust health coverage (health, dental, vision) covered up to 100% with FSA & HSA options
- One Medical membership and dedicated insurance advocates
- Fertility and family building benefits with Progyny
- Flexible time off
- 401(k) match
Last updated Oct 7, 2026. Interested? Apply on the company site.
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