Mechanical Project Engineer

Who we are:

Formic is on a mission to reshape American manufacturing by making automation accessible to every factory. As labor constraints rise, costs increase, and global competition intensifies, automation is no longer optional for manufacturers that want to stay competitive.

We deliver automation through a Robotics-as-a-Service model that combines industrial robotics, proprietary software, and full-service support into a single, integrated solution. By removing the traditional barriers of cost, complexity, and risk, we enable manufacturers to deploy automation quickly and realize measurable gains in throughput, safety, and operational efficiency without large upfront capital investment.

Backed by leading investors including Lux Capital, Initialized Capital, Blackhorn Ventures, and Mitsubishi HC Capital North America, Formic is scaling rapidly and building the foundation for a new era of high-performance, Made in America production.

About the team:

The Project Engineering team is a multidisciplinary engineering group within Automation Engineering Group, bringing mechanical, electrical, and controls engineering together under a single organization. The team serves as the engineering escalation path for the deployed fleet, taking on problems that exceed field-level troubleshooting and converting them into scoped, engineered, and standardized solutions.

The team's work spans three connected areas. The first is the troubleshooting of complex problems: diagnosing multi-discipline failures across deployed robotic systems and engineering permanent, root-cause fixes rather than repeat repairs. The second is continuous improvement: converting recurring issues and field data into reliability upgrades and fleet-wide standardization. The third is support for existing and new product development and enhancements, in partnership with teams across the organization, to improve equipment currently in the field and to bring new capability online.

Positioned at the intersection of design, commissioning, and field support, the team operates as a cross-functional unit, with engineers at the Bolingbrook hub working alongside field implementation resources across North America. The work is a deliberate blend of reactive support and proactive engineering, and each role on the team contributes to uptime, performance consistency, and long-term customer outcomes across the fleet.

About the role:

As a Mechanical Project Engineer, you will own the mechanical design, documentation, and commissioning of electromechanical systems and assemblies as they are developed, productized, and brought into Formic's automation portfolio. You will lead mechanical design efforts - from concept through SolidWorks modeling, drawing release, and BOM management - while also driving hands-on system integration and floor commissioning to ensure automation systems are proven and production-ready before they scale across Formic's fleet.

This is a hands-on, end-to-end role that blends mechanical design, EOAT development, and floor implementation with proactive product engineering. Working in close collaboration with Project Engineering and Software teams, you will design and release mechanical systems and end of arm tooling (EOAT), maintain organized model and drawing release structures, support the build and commissioning of automation systems on the floor, and develop the training and enablement material that equips Formic's fleet operations and deployment teams. Your work directly impacts mechanical design quality, deployment readiness, and the continued evolution and enhancement of Formic's automation portfolio.

In this role you will:

Own mechanical design of automation systems and assemblies — including palletizing systems, case packing systems, conveyor systems, material handling systems, and end of arm tooling (EOAT) — from concept through release

Design, prototype, assemble, and test automated end-of-line automation systems using SolidWorks 3D CAD

Develop and maintain organized SolidWorks model structures, assembly hierarchies, and controlled model/drawing release processes, including revision control and release documentation

Create and maintain detailed mechanical design documentation, including CAD models, drawings, exploded diagrams, BOMs, schematics, SOPs, and work instructions

Design EOAT and implement designs on the floor for build, integration, and commissioning of automation systems

Implement and integrate electrical, mechanical, and control subsystems, ensuring high performance, reliability, manufacturability, and repeatability

Rapidly iterate and validate mechanical designs and concepts to ensure exceptional product development delivery timelines

Lead and manage technical aspects of assigned automation projects within the product roadmap, ensuring milestones, technical specifications, and delivery timelines are met

Configure, validate, and troubleshoot electromechanical automation systems & assemblies on the floor during build and commissioning

Support design for manufacturability (DFM) and design for assembly (DFA) practices in collaboration with internal and external resources

Provide equipment support for Formic's Product & Software teams and technical operations teams

Collaborate with cross-functional teams to ensure cohesive product delivery and product sustainment

Troubleshoot & optimize; support debugging of system issues across software and hardware domains and recommend improvements to mechanical design and implementation

Participate in iterative development cycles by incorporating learnings from field deployments into mechanical design improvements

Perform root cause analysis, troubleshooting, and resolution of hardware and mechanical system-level issues

Develop and execute test plans to validate functionality, performance, and compliance with mechanical design requirements

Engage with external vendors to identify and scope necessary equipment and components

Interface with external system integrators and OEMs to ensure alignment on mechanical, electrical, and control design specifications

Continuously collect, aggregate, and assess Deployment and Production Optimization feedback for necessary mechanical design and Continuous Improvement enhancements

Prepare and deliver weekly internal reporting on progress for key initiatives

What makes you a great fit:

3+ years of experience in Mechanical Design, Mechanical Systems Engineering, Mechatronics, Robotics, or a related field

3+ years of experience designing mechanical systems, machine assemblies, or equipment for industrial automation and robotic applications

Experience owning mechanical designs from concept through manufacturing release, including full 3D assemblies, detailed drawings, component selection, and BOMs

Strong proficiency in 3D CAD, ideally SolidWorks, with experience designing complete machine or system assemblies, not just individual parts

Strong drafting and GD&T skills, with the ability to produce fabrication- and assembly-ready drawings, exploded diagrams, and BOMs

Familiarity with industrial robotic systems and their integration, including robotic arms such as FANUC, KUKA, ABB, Yaskawa, Universal Robots, or similar platforms

Strong understanding of how mechanical systems interface with robotics, EOAT, conveyance, sensors, actuators, guarding, and other automation components

Experience troubleshooting and diagnosing mechanical problems on automation systems or machinery

Willingness and ability to work hands-on on the shop floor, including mechanical assembly, integration, testing, troubleshooting, modification, and repair

Ability to organize and manage engineering deliverables through iterative development and tight feedback loops across concurrent projects

Excellent problem-solving, critical-thinking, communication, and cross-functional collaboration skills

Located in, or willing to