Motor Design Engineer

The Motor Design Engineer is responsible for the end-to-end design, analysis, and qualification of high-performance brushless DC (BLDC) motors and voice coil actuators (VCAs) for demanding Aerospace & Defense applications.

This role focuses on architecting electromagnetic topologies, optimizing motor/actuator performance for extreme environments, and supporting next generation propulsion, actuation, and stabilization systems for commercial and military aircraft, UAVs, missiles, electronic warfare platforms, and advanced aerospace systems.

The engineer will collaborate closely with Sales, Marketing, Manufacturing, Quality, Supply chain, and Customers to deliver robust, manufacturable, and compliant motor solutions that meet stringent industry standards

General Responsibilities

• Creates designs within inter-disciplinary teams to address complex product design and manufacturing challenges
• Leads feasibility studies and testing on new and modified designs
• Develops testing, engineering analysis, qualification testing, production launch
• Responsible for failure analysis investigations and engineering evaluations
• Maintains product documentation (drawings and specifications) and lessons learned; produce design reports, test reports, operating manuals and test procedures
• Leads a team that includes senior engineers/managers for the purpose of engaging with customers in soliciting product specifications requirements, schedule expectations and budget
  
  

Experience / Qualifications

• A university degree required (i.e. Bachelors degree) or equivalent relevant work experience
• Must be a team player able to work in a fast-paced environment with demonstrated ability to handle multiple competing tasks and demands
• Strong communication skills; oral, written and presentation
• Strong organization, planning and time management skills to achieve results
• Strong personal and professional ethical values and integrity
• Holds self-accountable to achieving goals and standards
• Proficient in Microsoft Office programs (Outlook, Word, PowerPoint, and Excel)
• Strong interpersonal & collaboration skills to work effectively with all levels of the organization including suppliers and/or external customers
• Design and develop Brushless DC motors, and Voice Coil Actuators for aerospace environments, which includes using software such as Altair Flux, ANSYS Maxwell, Motor-CAD, MagNet, JMAG, or similar tools to determine motor/actuator parameters and winding constants.
• Ensure compliance with AS9100 quality requirements and maintain rigorous configuration control and documentation standards.
• Conduct coupled thermal–electromagnetic simulations to ensure motor performance over extended aerospace temperature ranges (e.g., –55°C to 150°C).
• Work with mechanical counterparts to evaluate structural integrity under shock, vibration, and high-G loading per RTCA/DO-160 and MIL-STD-810.
• Using calculation results, perform all related engineering activities to prepare drawings and other documentation to build manufacturable prototypes.
• Working with QA department, create test plans, ATP’s and Test Data Sheets to execute qualification testing of the motors/actuators per customer-specific aerospace requirements and compliance with applicable standards.
• Partner with Sales, Applications Engineering, and Marketing to support customer engagements, technical reviews, proposals (RFI/RFQ), and requirements development.
• Engage with Quality, Supply Chain, and Strategic Sourcing to address component availability, risks, and cost optimization.
  
  

This position requires eligibility to obtain authorization under the International Traffic in Arms Regulations (ITAR) and/or the Export Administration Regulations (EAR). Non-US Persons, as defined in the ITAR and EAR, may not be eligible to obtain authorization.

Base Salary Range:

$107,800.00 - $148,280.00

At Sensata, our employees are the key to our success and growth. We recognize that each individual brings their own unique experience, therefore the base salary range information shown above is a general guideline only. Sensata considers several factors when extending an offer, including, but not limited to, a candidate’s experience and qualifications, as well as internal equity, market and business considerations. In addition to base salary, Sensata offers competitive medical, dental, vision, life and disability insurance plans, along with education reimbursement, wellness programs, a 401(k) retirement plan with Company matching, and a variety of paid time off, such as vacation or flex-time, sick, bereavement, and parental leave. Certain positions are also eligible for short-term incentive and long-term incentive programs.

SmarterTogether

• Collaborating at Sensata means working with some of the world’s most talented people in an enriching environment that is constantly pushing towards the next best thing
• Employees work across functions, countries and cultures gaining new perspectives through mutual respect and open communication
• As OneSensata, we are working together to make things work together
  
  

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