Sr. Motor Development Engineer

Primary Responsibilities

• Lead mechanical design, development, prototyping, testing, and troubleshooting for high complexity projects.
• Develop detailed component drawings with appropriate GD&T, tolerances, and material specifications for motor components and sub-assemblies.
• Evaluate and select materials and manufacturing processes — including injection molding, die casting, stamping, and machining — to optimize cost, quality, and performance.
• Maintain a strong working knowledge of BLDC motor manufacturing processes such as stator lamination stamping, stator winding, magnet assembly, pressing operations, and testing methods.
• Interpret motor and power system performance curves (torque-speed, efficiency maps, thermal profiles) to draw conclusions about tool-level performance and inform design decisions.
• Drive hands-on evaluation and testing in outdoor power tools.
• Establish and drive motor test plans and mechanical verification strategies, including vibration, durability, thermal, and environmental testing.
• Conduct root cause analysis of mechanical test failures and drive corrective actions through design or process improvements.
• Collaborate with electrical and controls engineers to ensure motor mechanical designs are compatible with electronic drive systems and application requirements.
• Interface with motor component suppliers to review designs, resolve quality issues, and support sourcing of laminations, magnets, shafts, and other motor parts.
• Represent the motor development team in cross-functional project meetings and provide clear technical communication and project updates.
• Frame up and lead technical tradeoff discussions with product management and other cross functional teams that focus on Cost, Schedule, and Performance impact.

Minimum Job Requirements

• Bachelor of Science in Mechanical Engineering or related field; advanced degree is a plus.
• 5+ years of experience in related design field.
• Strong mechanical design background with direct experience in injection molding, die casting, stamping, and machining processes.
• Familiarity with BLDC, Brushed PMDC, and AC motor design principles, motor topologies, and their application in power tools, outdoor equipment, or similar high-volume consumer products.
• Proficient with 3D CAD software and experienced with GD&T, tolerance analysis, and engineering drawings.
• Understanding of electronic systems and motor drive solutions as they relate to motor mechanical design and system integration.
• Understanding of motor assembly principles and motor component design/manufacturing and what drives cost and performance.
• Ability to travel 15% of the time (domestic and international).

Benefits

We offer competitive wages and a comprehensive benefits package – tuition assistance, 401(k), medical/dental/vision coverage, vacation and holidays.