
Staff Mechanical Design Engineer, Motor
- Tustin, CA
- $137,800-172,200 per year
- Permanent
- Full-time
Role SummaryAs the Staff Mechanical Design Engineer, Motor, you will have a critical technical role guiding and shaping the design, release, and integration of an electric motor. Specifically, technical responsibility for motor electromagnetic analysis, NVH analysis, thermal analysis, and performance analysis. You will work with purchasing to source components and work collaboratively with suppliers to ensure manufacturability at scale. You will develop DFMEAs and DVPRs to ensure robust analytical and physical validation.
Responsibilities
- Design mechanical components of stators, rotors, and their integration
- Iterate motor mechanical designs to optimize electromagnetic performance while ensuring manufacturability and cost-effectiveness
- Lead engineering on winding technologies, magnet materials, lamination methods, insulation, and electrical interconnections
- Design, model, and simulate electromagnetic components and systems using industry-standard software
- Develop detailed CAD drawings and manufacturing instructions
- Perform linear static stress and structural analyses on components under operational and dynamic loads.
- Execute and document Design Verification Plans & Reports (DVP&R)
- Develop and maintain Design Failure Mode and Effects Analyses (DFMEAs)
- Coordinate validation and quality assurance activities with Tier 1 and Tier 2 suppliers
- Collaborate across disciplines to advance designs from initial concept through prototyping to mass production.
- Support hands-on prototype assembly, testing, and component fabrication
- BS in Mechanical Engineering, Electrical Engineering, or a related field; MS preferred
- 5+ years of experience leading validation efforts in automotive or high-power product field
- Proficient in CAD tools (CATIA/3DExperience preferred) and PLM systems for component design, including BOM structuring and engineering change control.
- Proficient in industry-standard electromagnetic simulation
- Strong mechanical engineering foundation, with expertise in materials, heat treatments, statics, dynamics, and mechanics of materials
- Experienced in high-volume manufacturing techniques for electric motor components (e.g., stamping, winding, welding)
- Deep understanding of electric motor design parameters and their influence on torque, power, efficiency, thermal performance, and NVH
- Skilled in FEA using tools like Ansys, Abaqus, and HyperWorks; experienced with MATLAB and/or Python for performance modeling and data analysis
- Proficient in GD&T and tolerance stack-up analysis to ensure reliability
- Hands-on experience with integration, assembly, testing, and troubleshooting of electric motors