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OpenAI's Robotics team is seeking an Actuator Gear Design Engineer to lead the development of custom gears and gear stages for advanced robotic systems. This role owns actuator development from early architecture and concept generation through prototype validation and system integration, partnering closely with mechanical, electrical, controls, firmware, and reliability teams.
Key responsibilities include leading the architecture, design, and integration of custom robotic actuator gearing; defining actuator requirements and conducting system-level trade studies around torque density, bandwidth, efficiency, thermal performance, back drivability, inertia, reliability, manufacturability, and cost. You will design precision electromechanical assemblies with strong attention to tolerances, alignment, load paths, thermal expansion, sealing, wear, and serviceability.
The role involves driving actuator integration into robotic systems by partnering closely with controls, firmware, electrical, and robotics software teams to optimize closed-loop performance. You will develop and evaluate architectures with integrated sensing and encoder strategies, build and validate prototypes through hands-on bring-up, debugging, characterization, and iterative refinement.
Additional responsibilities include developing test methodologies and characterization infrastructure for actuator performance, reliability, durability, and failure analysis; analyzing test data to identify limitations and opportunities for design improvement; collaborating with manufacturing and supplier partners to transition designs from prototype to scalable production-ready assemblies; and supporting DFM, DFA, DFT, calibration, and assembly strategies.
You will contribute to actuator sourcing strategy, vendor qualification, prototype builds, and supply-chain development. Documentation of designs, interfaces, validation results, and engineering decisions is critical to support long-term maintainability and production readiness. The role also involves helping establish engineering standards, integration practices, and development workflows for future robotic platforms.
Ideal candidates are highly hands-on, enjoy operating at both subsystem and system levels, and can move fluidly between first-principles analysis, rapid prototyping, and production-oriented engineering decisions. Strong communication across disciplines and proactive cross-functional collaboration are essential. The role requires 5+ years of experience designing gear systems, robotic actuators, or precision mechatronic hardware, with strong understanding of motors, transmissions, bearings, encoders, structural design, and thermal management.
