Modal Motors
Electric Motor Designer / Engineer (DC Motors, EM FEA)
Role:
Design, model, and validate DC motors. Own electromagnetic finite element analysis from first principles through test correlation. Deliver torque, efficiency, thermal, cost, and manufacturability targets.
Responsibilities
Define motor requirements and translate into slot/pole, winding, magnet, and lamination choices.
Build 2D/3D EM FEA models; run parametric sweeps, sensitivity, and optimization.
Predict back-EMF, torque ripple, cogging, losses (Cu, core, eddy, stray), and efficiency maps.
Size thermal paths; couple EM → thermal; estimate temp rise and demag margins.
Specify magnets, steels, wire, insulation, adhesives, potting, bearings, and housings.
Produce drawings, stack-ups, and tolerances; partner with ME for fits and NVH.
Plan DVP&R; define fixtures and test methods; correlate simulation to dynamometer data.
Drive DFMEA, risk burndown, and design changes for yield and reliability.
Support suppliers on laminations, winding, magnetization, balancing, and assembly.
Document results; present trade studies and design decisions to stakeholders.
Automate workflows with scripts; version control all models and data.
Required Qualifications
BS/MS in Mechanical, Electrical, or Mechatronics Engineering (or equivalent).
5+ years designing DC motors: brushed, PMDC, or BLDC/PSC; outer or inner runner.
Expert with EM FEA tools: ANSYS Maxwell, JMAG, Altair Flux, Motor-CAD, or FEMM.
Strong electromagnetics, materials, and motor theory: B-H curves, hysteresis/eddy loss, saturation, demag, leakage, end effects.
Proven correlation of FEA to test; understands test uncertainty and instrumentation.
Thermal modeling experience: conduction, convection, potting, slots, and end-turn cooling.
Working knowledge of controls and drive electronics impacts on design.
CAD proficiency and drawing control (GD&T).
Clear technical writing and data presentation.
Preferred Skills
Experience with high-volume manufacturing: lamination stacks, skewing, hairpin or concentrated windings, automated magnetization.
NVH mitigation and torque ripple reduction methods, incl. skew, fractional slots, and shaping.
IP sealing, insulation systems, creepage/clearance, and safety standards.
Design for cost and supply risk; non-rare-earth magnet options.
Scripting for automation: Python or MATLAB; optimization frameworks (DOE, GA).
System integration in vehicles, robotics, industrial, or aerospace.
Tools You Should Know Well
Test: dynamometer, power analyzers, oscilloscopes, thermal sensors/IR, torque sensors.
What Success Looks Like
Motors that meet torque-speed, efficiency, thermal, NVH, and cost targets.
Verified models that predict test within agreed error bands.
Released drawings/BOMs ready for sourcing and build.
Location and Work
Onsite. Some travel to vendors and test labs.
All qualified applicants considered without regard to race, creed, ethnicity, etc.
How to Apply Send resume along with two relevant motor design examples and FEA screenshots.
#J-18808-Ljbffr
Design, model, and validate DC motors. Own electromagnetic finite element analysis from first principles through test correlation. Deliver torque, efficiency, thermal, cost, and manufacturability targets.
Responsibilities
Define motor requirements and translate into slot/pole, winding, magnet, and lamination choices.
Build 2D/3D EM FEA models; run parametric sweeps, sensitivity, and optimization.
Predict back-EMF, torque ripple, cogging, losses (Cu, core, eddy, stray), and efficiency maps.
Size thermal paths; couple EM → thermal; estimate temp rise and demag margins.
Specify magnets, steels, wire, insulation, adhesives, potting, bearings, and housings.
Produce drawings, stack-ups, and tolerances; partner with ME for fits and NVH.
Plan DVP&R; define fixtures and test methods; correlate simulation to dynamometer data.
Drive DFMEA, risk burndown, and design changes for yield and reliability.
Support suppliers on laminations, winding, magnetization, balancing, and assembly.
Document results; present trade studies and design decisions to stakeholders.
Automate workflows with scripts; version control all models and data.
Required Qualifications
BS/MS in Mechanical, Electrical, or Mechatronics Engineering (or equivalent).
5+ years designing DC motors: brushed, PMDC, or BLDC/PSC; outer or inner runner.
Expert with EM FEA tools: ANSYS Maxwell, JMAG, Altair Flux, Motor-CAD, or FEMM.
Strong electromagnetics, materials, and motor theory: B-H curves, hysteresis/eddy loss, saturation, demag, leakage, end effects.
Proven correlation of FEA to test; understands test uncertainty and instrumentation.
Thermal modeling experience: conduction, convection, potting, slots, and end-turn cooling.
Working knowledge of controls and drive electronics impacts on design.
CAD proficiency and drawing control (GD&T).
Clear technical writing and data presentation.
Preferred Skills
Experience with high-volume manufacturing: lamination stacks, skewing, hairpin or concentrated windings, automated magnetization.
NVH mitigation and torque ripple reduction methods, incl. skew, fractional slots, and shaping.
IP sealing, insulation systems, creepage/clearance, and safety standards.
Design for cost and supply risk; non-rare-earth magnet options.
Scripting for automation: Python or MATLAB; optimization frameworks (DOE, GA).
System integration in vehicles, robotics, industrial, or aerospace.
Tools You Should Know Well
Test: dynamometer, power analyzers, oscilloscopes, thermal sensors/IR, torque sensors.
What Success Looks Like
Motors that meet torque-speed, efficiency, thermal, NVH, and cost targets.
Verified models that predict test within agreed error bands.
Released drawings/BOMs ready for sourcing and build.
Location and Work
Onsite. Some travel to vendors and test labs.
All qualified applicants considered without regard to race, creed, ethnicity, etc.
How to Apply Send resume along with two relevant motor design examples and FEA screenshots.
#J-18808-Ljbffr