Senior Mechanical Design Engineer

Advanced Technology Electric Motor Structures Development Pay: Based on relevant experience and qualifications Solve difficult engineering problems and see what you build become real. At Modal Motors, your designs don't wait in a queue. You will take housings, shafts, and thermal features from CAD to a prototype on the bench, test them, and help carry them into production. COMPANY OVERVIEW Modal Motors, Inc. is an advanced electric motor technology startup developing next-generation, high-efficiency Claw Pole Transverse Flux DC motor systems for mobility, robotics, and industrial applications. Our engineering team combines advanced modeling, rapid prototyping, and hands-on testing to develop practical solutions to complex electromechanical challenges. POSITION SUMMARY We are seeking a Senior Mechanical Design Engineer with a demonstrated ability to lead engineering projects and take ownership of complex mechanical and electromechanical assemblies from concept through validation and production readiness. Reporting to the Director of Mechanical Engineering, you will lead assigned development projects while remaining directly involved in CAD design, analysis, prototype builds, and testing. You will translate requirements into manufacturable designs, coordinate work across disciplines and suppliers, mentor junior engineers, and make sound engineering decisions that balance performance, reliability, cost, and schedule. KEY RESPONSIBILITIES Lead assigned mechanical development projects, defining scope, deliverables, milestones, resource needs, and technical risks; communicate progress and resolve issues that affect delivery. Develop and evaluate motor architectures, components, and assemblies, including housings, shafts, bearings, rotor and stator supports, and thermal management features. Create and review 3D CAD models, detailed drawings, geometric dimensioning and tolerancing (GD&T), and tolerance stack-ups using CATIA, SolidWorks, or compatible platforms. Perform structural and thermal finite element analysis (FEA), supported by engineering calculations and test results, to guide design decisions. Coordinate with electromagnetic, electrical, controls, and manufacturing engineers to resolve interfaces and achieve system requirements. Lead design reviews and assess failure modes, documenting technical decisions, corrective actions, and verification requirements. Work with suppliers on material and process selection, quotations, technical requirements, and design for manufacturability and assembly (DFM/DFA). Lead prototype assembly, dimensional inspection, troubleshooting, and root-cause analysis; use findings to improve subsequent designs. Develop validation plans with measurable acceptance criteria, oversee testing, and confirm that designs meet requirements before release. Maintain accurate bills of materials, engineering changes, revision control, and drawing release packages; mentor junior engineers and review their technical work. REQUIRED QUALIFICATIONS 10+ years of experience in mechanical design or product development, including substantial responsibility for complex assemblies. Demonstrated success leading engineering projects from requirements and concept development through prototype testing and design release. Advanced proficiency in SolidWorks, CATIA, or comparable 3D CAD software, including assembly modeling and detailed engineering drawings. Practical experience with structural and thermal FEA, including selecting appropriate assumptions and boundary conditions and checking results against calculations or tests. Strong working knowledge of GD&T, tolerance analysis, material selection, precision fits, and manufacturing processes. Hands-on experience developing and troubleshooting electromechanical systems or rotating machinery. Ability to prioritize work independently, guide other engineers, coordinate suppliers, and communicate technical decisions and project risks clearly. Must be a US Citizen. PREFERRED QUALIFICATIONS Bachelor's or master's degree in mechanical engineering or a related field. Equivalent relevant experience is valued; a degree is not required. Experience with electric motors, actuators, robotics, or other precision motion systems; familiarity with transverse flux or magnetic assemblies is a plus. Experience with ANSYS or comparable simulation tools, design failure mode and effects analysis (DFMEA), and product data management systems. Experience with machining, casting, stamping, laminations, powder metallurgy, or injection molding, and transitioning prototypes into repeatable production. WORK ENVIRONMENT This is an on-site position in Farmington Hills, Michigan, combining design work with prototype assembly and laboratory testing. Success requires initiative, practical judgment, and a collaborative approach in a startup environment with evolving priorities. BENEFITS Paid time off EQUAL EMPLOYMENT OPPORTUNITY Modal Motors, Inc. is an Equal Opportunity Employer. Employment decisions are based on qualifications, merit, and business need. We do not discriminate on the basis of race (including traits historically associated with race, such as hair texture and protective hairstyles), color, religion, national origin, sex, pregnancy, sexual orientation, gender identity or expression, age, height, weight, marital status, familial status, disability, genetic information, protected veteran status, or any other characteristic protected by federal, state, or local law. Modal Motors provides reasonable accommodations to qualified applicants with disabilities. If you need an accommodation at any point in the application or interview process, contact View email address on click.appcast.io. #J-18808-Ljbffr