MGU Mechanical Design Engineer

Job Summary

We’re seeking a detail-oriented MGU E-Motor Mechanical Design Engineer to join our high-performance Formula 1 Energy Recovery System (ERS) team located in Concord, NC. In this critical role, you will drive the mechanical design and development of the Motor Generator Unit (MGU) e-motor, focusing on structural optimization, rotor-stator integration, and mechanical system reliability under extreme racing conditions. You will create precise 3D models, detailed technical drawings, and run advanced simulations using state-of-the-art CAD and CAE tools to ensure performance and mechanical integrity of the MGU components. You will collaborate closely with cross-disciplinary teams including electromagnetic engineers, electrical controls, thermal management, and manufacturing experts to optimize the mechanical-electrical integration and packaging of the MGU within the hybrid powertrain.

Key Responsibilities

• Lead mechanical design of MGU components, including rotors, stators, bearings, housings, and thermal interfaces.
• Collaborate closely with the electromagnetic engineering team to optimize mechanical and electromagnetic integration for maximal motor performance and efficiency.
• Utilize machine learning (ML) techniques and Design of Experiments (DoE) to systematically explore design variables and optimize mechanical components.
• Develop designs controlling rotor dynamics to minimize eccentricity, vibration, and runout.
• Perform finite element and tolerance analyses to ensure structural integrity under high-speed operation.
• Support prototype development, testing, and data analysis including vibration and thermal monitoring.
• Collaborate with electrical, controls, and manufacturing teams to ensure seamless system integration.
• Manage design reviews, documentation, and compliance with Formula 1 technical regulations.
• Drive continuous innovation by researching new materials, fabrication technologies, and mechanical design methods for motorsport electric machines.

Required Qualifications

• Bachelor’s degree in Mechanical Engineering or related discipline with a minimum of 5 years of relevant mechanical design experience in high-speed electric motors or motorsport applications.
• Alternatively, Master’s degree or PhD in Mechanical Engineering or related discipline with at least 2 years of demonstrated expertise in designing mechanical systems for electric machines or Formula 1 power units.
• Proficient in 3D CAD software (CATIA, NX, or SolidWorks) and finite element analysis tools.
• Strong understanding of rotor-stator dynamics, shaft alignment, and eccentricity mitigation techniques.
• Experience with precision bearing selection and integration (e.g., ceramic or hybrid bearings).
• Skilled in vibration analysis, dynamic balancing, and tolerance stack-up methods.
• Hands-on experience with prototype testing, instrumentation, and performance data interpretation.
• Knowledge of Formula 1 technical regulations, particularly those governing MGU components, rotor-stator integration, and power unit mechanical interfaces.
• Experience or familiarity with machine learning methods for design optimization and application of Design of Experiments (DoE) to motor design problems is a plus.

Preferred Qualifications

• Familiarity with F1 technical regulations, particularly those governing MGU components, rotor-stator integration, and power unit mechanical interfaces.
• Experience with CAE/FEA tools like ANSYS for thermal-structural simulations of high-speed e-motor rotors, stators, and bearing systems under F1 operating conditions.
• Hands-on experience in motorsport MGU prototyping, dynamometer testing, or cross-functional collaboration in hybrid ERS powertrains; preference for Formula SAE electric/hybrid powertrain participants.
• Knowledge of advanced materials (e.g., carbon composites, titanium alloys) and manufacturing processes like composite rotor housings, high-precision CNC rotor machining, and additive manufacturing.
• Knowledge of Design for Manufacture/Assembly (DFM/DFA) principles and tooling/jig design for MGU e-motor assembly and precision balancing fixtures.
• Experience conducting Failure Modes and Effects Analysis (FMEA) for high-speed rotating machinery and e-motor systems to identify and mitigate design risks.
• Understanding of engineering drawing standards (GD&T) and quality management systems for motorsport MGU components.
• Knowledge of PLM systems (e.g., Teamcenter) for MGU design version control.

Personal Attributes

• Detail-oriented with a strong commitment to precision engineering and quality.
• Proactive problem solver who anticipates challenges and drives innovative solutions.
• Able to work effectively under pressure in a fast-paced, deadline-driven motorsport environment.
• Strong collaborator with excellent communication skills for cross-functional teamwork.
• Adaptable and open to continuous learning, embracing new technologies and methodologies.
• Self-motivated with a drive for excellence and continuous improvement in high-performance engineering.
• Highly organized with strong time management skills to handle multiple tasks and priorities simultaneously.

Benefits

Includes Access To Bonus scheme
Private healthcare
401(k) plan including company match
Employer-paid life insurance and disability coverage
32 days annual leave (including holidays)
Free financial advisor access
Employee Assistance Programs (EAP)
Subsidized on-site dining
On-site gym
Discounted GM vehicle purchase/lease program
Free on-site EV charging for personal GM vehicles

Pay

Competitive compensation package tailored to individual performance and experience.

Schedule

Full-time position with flexible working hours to accommodate the demands of motorsport operations.