Senior Mechanical Engineer at Bots Unlimited

San Antonio, Texas, United States -

Full Time

Start Date

Immediate

Expiry Date

24 May, 26

Salary

0.0

Posted On

23 Feb, 26

Experience

5 year(s) or above

Remote Job

Yes

Telecommute

Yes

Sponsor Visa

Skills

Mechanical Design, Electromechanical Subsystems, Product Enclosures, 3D CAD, SolidWorks, Autodesk Inventor, Creo, Injection Molding, CNC Machining, GD&T, Tolerance Analysis, PLM System, DFM/DFMA, Vendor Coordination, Validation Testing, BLDC Motors

Industry

Manufacturing

Description

About Bots Unlimited Bots Unlimited is a San Antonio based product development and hardware company that designs, produces, and supports high performance technology for drones, robotics, automation, and edge AI systems. We create advanced camera modules, long range wireless solutions, embedded compute platforms, and propulsion electronics, working closely with trusted manufacturing partners to deliver reliable hardware with a globally resilient supply chain. We also provide customers with supply chain support and manufacturing services to help bring complete products to market. We operate in a fast moving, execution focused environment where team members own their work end to end and are trusted to manage themselves with a high level of accountability. Our team values initiative, clear communication, and a strong sense of responsibility, qualities that let us move quickly and ship production-ready hardware. If you thrive in a setting where you can take full ownership, solve complex challenges, and build products used in real world scenarios, we may be the right fit for you! Position Overview We are seeking a highly experienced Senior Mechanical Engineer to lead the end-to-end mechanical development of our robotics and drone hardware. This is a high-impact, hybrid role requiring a rare combination of expertise: you will own the mechanical design for both high-performance electromechanical subsystems (brushless DC motors, rotating assemblies) and product enclosures (precision plastics, protective sleeves, and ruggedized housings). We are looking for self-managed, Type A personalities: people who thrive in fast-moving environments, can work independently, and push projects forward without constant direction. Your work will directly enable our Bots Unlimited product lineup, turning complex motor and enclosure concepts into production-ready hardware that meets tight tolerance, thermal, and aesthetic requirements. This is a hands-on, onsite role based in San Antonio, TX. You will work closely with electrical, test, and manufacturing teams in our lab environment to build, validate, and iterate on real hardware. Our team operates at startup speed, and you’ll be expected to contribute directly to hardware that ships to customers on aggressive timelines. Key Responsibilities Plastics & Enclosures: Lead the design and engineering of high-precision mold injected plastic enclosures, including cell phone-style sleeves, protective cases, and internal mounting structures. Electromechanical Design: Develop 3D CAD models for motors, housings, rotor/stator sub-assemblies, shafts, and bearings. Lifecycle Management: Own the full design lifecycle from concept through detailed CAD modeling, drawing release, and manufacturing support. Technical Documentation: Produce full mechanical drawings including GD&T, tolerance stacks, material specifications, and surface-finish details for both machined metal and injection-molded parts. PLM & Data Management: Manage and maintain mechanical data, part numbers, and revision control within the Duro PLM system (or equivalent). DFM/DFMA: Perform rigorous reviews to ensure designs are optimized for injection molding, CNC machining, and rapid assembly. Vendor Coordination: Interface with global vendors to issue RFQs, review vendor drawings, negotiate tolerances, and manage prototype/production builds. Validation & Testing: Lead mechanical validation (vibration, thermal, drop testing, and lifecycle durability) and record physical test data. Required Qualifications Education: Bachelor’s or Master’s degree in Mechanical Engineering or equivalent experience. Experience: 5–10+ years of professional mechanical design experience. Dual Expertise: Proven track record designing both high-volume mold injected plastic products (e.g., consumer electronics, phone cases, rugged enclosures) and rotating equipment/motors. CAD Mastery: Expert proficiency in 3D CAD (SolidWorks, Autodesk Inventor, or Creo) with the ability to manage complex assemblies and detailed 2D drawings. Manufacturing Knowledge: Deep understanding of injection molding (tooling, draft, sink, gates) and CNC machining processes. Technical Standards: Solid understanding of GD&T, tolerance analysis, and material properties (polymers, resins, and alloys). Systems Tools: Experience using PLM/PDM systems (e.g., Duro, Windchill) to manage part revisions and BOMs. Hands-on Skills: Proficiency with calipers, micrometers, and lab tools for physical prototype validation and fit/clearance checks. Communication: Excellent verbal and written skills; ability to work onsite in San Antonio and travel periodically for vendor visits or product milestones. Preferred Qualifications Prior experience with brushless DC (BLDC) motors or electromechanical actuators. Experience in overmolding, ultrasonic welding, or advanced plastic finishing processes. Background in rotor balancing, vibration analysis, or thermal management for electronics. Previous experience with supplier sourcing and DFM for mass production. Familiarity with rotating systems safety standards and impact resistance for mobile devices. Physical and Mental Requirements Ability to sit and/or stand for periods of time. Ability to use a keyboard, mouse, and other equipment with or without accommodation(s). Ability to maintain awareness during business hours. Ability to lift 15 pounds. [MAYBE MORE IF WAREHOUSE] Excellent written and verbal communication and good command of the English language. Ability to learn and memorize routine tasks. Reasonable accommodations will be provided to any person with a disability to be able to perform the essential job functions of this position. Company retains the right to change or assign other duties as required for this position. Selection Process Hiring team reviews applications 15-minute pre-screen with recruiter 30-minute phone screen with the hiring manager Take home project In-person or video interview with hiring team Benefits Comprehensive medical plans with Rx 100% employer paid dental and vision insurance premiums Automatic 401k employer contribution with vesting Paid vacation and personal time off 11 Paid holidays 5 days of sick leave We are an equal-opportunity employer and prohibit discrimination and harassment against any employee or applicant because of race, color, gender (including pregnancy), age, gender identity, creed, religion, national origin, sexual orientation, marital status, genetic information, disability, political affiliation, protected veteran status, or any other status protected by federal, state, or local law.

Responsibilities

The Senior Mechanical Engineer will lead the end-to-end mechanical development for robotics and drone hardware, focusing on both high-performance electromechanical subsystems like motors and product enclosures such as precision plastics and ruggedized housings. Key duties include owning the full design lifecycle, producing detailed technical documentation with GD&T, managing data in the PLM system, and coordinating with global vendors for manufacturing.