Principal Mechanical Engineer

Overview We are seeking an experienced and technically strong Principal Mechanical Engineer to lead the design and development of electric machine systems within a cutting-edge engineering environment. This role focuses on the mechanical design, thermal performance, and integration of electric motors, ensuring robust, reliable, and manufacturable solutions. You will work across the full product lifecycle—from concept through validation and production—playing a key role in delivering high-performance motor designs that meet real-world operating requirements. This is a senior-level position with significant ownership, technical leadership, and cross-functional collaboration. Schedule Shift: Monday–Friday Hours: 8:30 AM – 5:00 PM Overtime: Additional hours may be required based on business needs Key Responsibilities Lead the mechanical design and integration of electric machines, including rotor, stator, shaft, bearings, and housing systems Develop rotor constructions, including magnet selection, placement, and retention strategies Ensure structural integrity under high-speed conditions, including fatigue and containment considerations Define and implement thermal management strategies, including airflow and cooling system design Design and integrate key motor components, including stator windings, insulation systems, and flux paths Integrate sensing solutions such as speed, position, and temperature sensors Collaborate with electromagnetic and controls teams to translate performance targets into practical designs Perform and guide engineering analysis including stress, deformation, vibration, and thermal behavior Lead FMEA activities, risk identification, and root cause investigations Define and execute test and validation plans for performance, durability, and thermal requirements Work closely with test teams to ensure accurate data collection and validation of design intent Review test results, identify issues, and drive continuous design improvements Ensure designs are suitable for manufacturing, including assembly methods, tooling, and cost considerations Support internal and customer-facing discussions by clearly communicating technical decisions and outcomes Qualifications Degree in Mechanical Engineering or related discipline Proven experience in electric machine design with a focus on mechanical and thermal systems Experience designing rotor systems, including magnet retention and high-speed operation Knowledge of stator construction and winding integration Hands-on experience with motor build, testing, and validation Experience leading FMEA and failure analysis activities Understanding of air-cooled thermal management systems Experience working within cross-functional engineering teams Core Competencies Strong technical expertise in electric machine design Analytical thinking and problem-solving capability Ability to balance performance, durability, manufacturability, and cost Structured, data-driven decision-making approach Effective communication and stakeholder engagement Leadership and ownership mindset Equipment & Technologies Mechanical and thermal analysis tools CAD and engineering design software Motor testing and validation systems Materials used in electric machines (electrical steel, magnets, conductors) Engineering documentation and reporting tools