Principal Motor Design Engineer (Electric Machines)

Principal Motor Design Engineer (Electric Machines)

Location: Baton Rouge LA or Glendale AZ

Type: Full-time

Client: Confidential aerospace and defense contractor

Intrepidus Talent Solutions is running a search for an aerospace and defense contractor that designs and builds mission-critical electromechanical hardware for the Department of Defense and major prime contractors. Our client needs a Principal Motor Design Engineer to own electric motor design from start to finish and be the companys senior technical authority on electric machines.

The right person sees a motor as one complete rotating system. Electromagnetic performance matters and so do thermal structural rotordynamic bearing tolerance materials drivetrain manufacturing and test factors. Youll take designs from requirements through analysis prototype qualification and into production working mainly on permanent magnet synchronous (PMSM) brushless DC (BLDC) and AC synchronous motors.

Design and Analysis

Lead design of PMSM BLDC AC synchronous and specialty motors from requirements definition through production release

Turn system and customer requirements into motor-level requirements interfaces detailed specifications and verification criteria

Run electromagnetic design and simulation in ANSYS Motor-CAD and related ANSYS tools: magnetic circuits windings torque losses efficiency and performance

Perform and support coupled thermal structural stress and dynamic analysis covering winding and magnet temperatures thermal paths and growth fatigue shock vibration and overspeed

Lead trade studies across electromagnetic thermal structural mechanical manufacturing reliability cost and SWaP considerations

Rotating Assembly and Mechanical Design

Design the full rotating assembly including rotors shafts housings bearing systems magnet retention and interfaces

Evaluate rotor dynamics (critical speeds rotor stiffness bearing effects unbalance response resonance risk) and own balancing strategy balance correction and vibration troubleshooting

Select and analyze bearings for load capacity life preload fits lubrication stiffness and thermal and environmental effects

Develop GD&T schemes and tolerance stack-ups for air gaps bearing fits rotor/stator concentricity runout and other critical dimensions

Integrate motors with gearboxes couplings splines actuators and other drivetrain components

Select materials and assess compatibility (magnetic insulation structural bearing adhesive coating lubricant) accounting for temperature environment corrosion CTE mismatch outgassing and manufacturing processes

Build Test and Production

Produce CAD models engineering drawings tolerance requirements BOMs and design documentation to applicable aerospace and defense standards

Apply DFM/DFA principles and work with manufacturing suppliers and quality so designs can be built assembled inspected balanced and tested repeatably

Oversee prototype builds bench testing environmental qualification endurance testing failure analysis and teardowns then correlate results to analytical models and refine the design

Make sure designs meet requirements for performance reliability EMI/EMC environmental survivability manufacturability and SWaP

Technical Leadership

Serve as the principal technical point of contact in motor and electromechanical design reviews with customers primes and government stakeholders

Mentor junior and mid-level engineers and provide technical leadership across motor and electromechanical work

Partner with electrical mechanical systems controls manufacturing and test engineering to ensure integrated system performance

Support new business through technical volumes design concepts trade studies and ROM estimates

Work Environment

• Office engineering lab test and production settings with regular hands-on work on prototype and production hardware
  
• Occasional travel to customer sites test facilities and suppliers
  

All inquiries are handled confidentially. Our client is an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race color religion sex sexual orientation gender identity national origin disability or veteran status.

Requirements

What You Bring

• Bachelors in Electrical Mechanical or Electromechanical Engineering or a related field; Masters or PhD preferred
  
• 10 years designing electric motors rotating electromechanical systems or similar high-performance machinery ideally in aerospace defense or another high-reliability industry
  
• Deep electric machine design expertise in PMSM BLDC AC synchronous or similar machines including magnetic circuits winding design losses efficiency torque production and thermal management
  
• Hands-on ANSYS Motor-CAD plus ANSYS or equivalent tools for electromagnetic thermal structural or mechanical analysis
  
• Proven ability to judge a motor design beyond electromagnetics: thermal behavior structural integrity rotor dynamics bearings balancing mechanical interfaces and drivetrain
  
• GD&T engineering drawings tolerance analysis and stack-ups dimensional fits and precision rotating assemblies
  
• Material selection and compatibility for high-performance electromechanical hardware
  
• Full-lifecycle experience: requirements review specification concept detailed analysis CAD and drawings prototype test qualification and production transition
  
• Strong understanding of motor control fundamentals and how motors interact with drive electronics
  
• Working knowledge of MIL-STD-810 MIL-STD-461 MIL-STD-704 AS9100 and related standards
  
• Strong first-principles engineering troubleshooting root-cause analysis technical writing and communication skills
  
• Experience presenting designs and analysis to customers internal design reviews and government stakeholders
  
• U.S. citizenship required (government contracts and access to export-controlled information)
  

Nice to Have

• Integrated electromechanical actuators gearboxes couplings splines and mechanical drivetrains
  
• Rotor dynamics bearing analysis balancing vibration analysis and high-speed rotating machinery
  
• FMEA/FMECA reliability engineering design-for-reliability and life prediction
  
• DoD or NASA program experience including formal PDR/CDR and qualification testing
  
• Active DoD security clearance
  
• Experience mentoring engineers or leading small multidisciplinary technical teams
  

Required Skills:

What You Bring Bachelors degree in Engineering Program Management Business Operations Physics or a related technical field 5 years of relevant aerospace and defense government contracting engineering or technical program management experience Experience managing complex technical or hardware development programs through multiple phases of the product lifecycle Working knowledge of EVM/EVMS Experience building and maintaining WBS and IMS Familiarity with MIL-STD-881 or an equivalent product-oriented WBS method Experience with critical-path scheduling variance analysis recovery planning program budgets forecasts and EACs Experience leading multidisciplinary engineering manufacturing supply chain quality and test teams Ability to manage multiple priorities and concurrent program activities Strong understanding of government contracting and customer-facing program execution Strong written verbal organizational and presentation skills Proficiency with Microsoft Project or comparable scheduling software U.S. citizenship required Nice to Have 8 years of aerospace and defense program management engineering manufacturing or technical leadership experience Experience managing multimillion-dollar A&D development or production programs Experience working with the Department of Defense defense primes or aerospace OEMs Working knowledge of EIA-748 EVMS principles and DoD acquisition processes Experience with Firm-Fixed-Price and cost-type contracts Familiarity with military and aerospace qualification standards and formal customer design reviews Familiarity with FAR/DFARS ITAR/EAR AS9100 configuration management CDRLs/SDRLs and government contracting requirements Experience with Deltek Costpoint ERP/MRP PLM/PDM or similar enterprise systems Advanced degree or PMP certification