Tagged: Electric Motor Design, Bearing Selection, CREO, Tolerance Stack-up, FEA, Brushless DC Motor, solidworks, Aerospace, GD&T, BLDC, Additive Manufacturing, Finite Element Analysis, Rotor Design, Defense
Sr. Mechanical Engineer – Motor Design & Development
Location: Chaska, MN (On-site)
Employment Type: Full-Time
Compensation: $110,000 – $130,000/year + quarterly bonus
Our client is a growing precision manufacturing company specializing in the design and production of high-performance electric motors for aerospace and defense applications. They're looking for a Senior Mechanical Engineer to join their engineering team and take ownership of mechanical design work across the full product lifecycle — from concept through qualification and production support.
What You'll Do
- Design electric motors in close collaboration with electromechanical design engineers to meet customer performance requirements
-
Design rotors, housings, endcaps, and other mechanical assemblies
-
Size and select bearings to meet load and life requirements
-
Create and revise engineering drawings with proper GD&T; maintain accurate BOMs
-
Design manufacturable, cost-effective hardware — balancing tolerance stack-ups, assembly ease, materials, manufacturing methods, thermal/vibration environments, and mistake-proofing
-
Run preliminary analysis (hand calcs and FEA) to validate designs
-
Investigate and resolve non-conforming hardware and production/vendor issues
-
Lead or support failure investigations
-
Develop and approve assembly, test, and qualification processes
-
Interface directly with internal and external customers on product requirements and changes
-
Participate in design reviews and support new business proposals
What You Bring
- Bachelor's degree in Mechanical Engineering
-
Experience in 3D modeling of mechanical components/assemblies (CREO strongly preferred)
-
Experience with Brushless DC (BLDC) motor design and operation
-
Experience with Finite Element Analysis (FEA) — structural, thermal, and dynamic
-
Strong technical problem-solving using a methodical, data-driven approach
-
Working knowledge of manufacturing processes: additive manufacturing, casting, milling, turning, grinding, drilling
-
Strong organizational skills with the ability to manage multiple concurrent projects
-
Excellent verbal and written communication skills; comfortable presenting in cross-functional design reviews
-
Must be a U.S. Citizen (ITAR/export control requirement)
Nice to Have
- Prior experience in aerospace, defense, or other highly regulated manufacturing environment
-
Leadership experience coordinating across engineering, manufacturing, quality, and purchasing teams
Work Environment
- Split between professional office and manufacturing/machine shop settings
-
Some exposure to fluids, fumes, noise, vibration, and moving mechanical parts typical of a machine shop
-
Ability to stand for extended periods (7-8 hrs/day), walk, bend, and occasionally lift up to 50 lbs
-
~15% travel
Benefits
Competitive base salary plus quarterly bonus, medical/dental/vision, life and disability insurance, 401(k) with company match, generous tuition assistance, paid vacation/sick/personal time, paid holidays, and flexible/compressed work week options.
Equal Opportunity Employer – M/F/IWD/Veterans. Veterans encouraged to apply.
Compensation $130,000.00
Salary Range $110,000 - $130,000
Posted: Friday, July 31, 2026
Job # 959
