Job Title: Mechanical/Electromechanical Engineer - Robotic Servo Motor & Gearbox Design

Trossen Robotics

Location: Downers Grove, IL

Job Type: Full-Time

Company Overview:

Trossen Robotics is an industry leader in the field of research. We specialize in the design, development, and integration of machine learning manipulators and mobile platforms. Trossen Robotics platforms are in use by every major university and research institution in the USA along with fortune 100 tech companies in a variety of industries. Trossen is rapidly growing and is in the process of building out a team of A players to capitalize on the exploding industry of robotics and AI. This is an opportunity to get in on the ground floor of a company that is in the red hot center of an emerging industry.

Position Summary:

We are seeking a highly skilled and detail-oriented engineer with deep experience in the design of robotic servo motors and integrated gearboxes. This role is central to our product development pipeline and requires hands-on expertise in electromechanical design-from motor winding optimization and magnetic circuit design to high-efficiency gearbox integration.

Key Responsibilities:

• Lead the mechanical and electromechanical design of custom robotic servo motors, including rotor/stator layout, coil winding design, and magnetic performance tuning
• Design precision gearboxes (planetary, harmonic, cycloidal, etc.) optimized for high-torque, compact robotic joints
• Perform multi-domain modeling (mechanical, electrical, thermal) to optimize performance, weight, and reliability
• Collaborate closely with PCB, control, and software teams to ensure servo performance aligns with system-level requirements
• Run FEA simulations (thermal, magnetic, structural) and oversee prototype development and testing
• Interface with suppliers for sourcing, manufacturing, and DFM guidance of stator/rotor components, gearsets, and integrated housings
• Troubleshoot and iterate on motor-gearbox performance issues during bench and in-system testing

Required Qualifications:

• B.S. or M.S. in Mechanical Engineering, Electrical Engineering, Mechatronics, or related field
• 5+ years of experience in servo motor design, including stator/rotor construction, winding patterns, magnetics, and slot fill optimization
• Proven background in the design and integration of gearboxes for robotics or motion control systems
• Proficient with CAD (e.g., SolidWorks, Creo) and FEA tools (ANSYS, JMAG, or similar)
• Familiarity with torque-density tradeoffs, efficiency loss modeling, and real-world design-for-manufacturing practices
• Strong understanding of motor control feedback systems and how mechanical tolerances affect control performance

Preferred Qualifications:

• Experience with BLDC or frameless motor design
• Background in direct-drive or back-drivable actuation systems
• Familiarity with high-volume or precision manufacturing processes for motor components and gears
• Robotics industry experience, especially arm/joint actuators or humanoid applications