Job Description

The Senior Motor Design Engineer is responsible for leading the design and development of advanced Brushless DC (BLDC) Motors, Voice Coil Actuators (VCAs), and other precision electromagnetic motion-control solutions for Aerospace & Defense applications.

This role is responsible for the electromagnetic design, analysis, optimization, and validation of high-performance motors and actuators used in mission-critical systems including unmanned aircraft systems (UAS), missile guidance and control, avionics, gimbal stabilization, electro-mechanical actuation, and next-generation aerospace platforms. The ideal candidate possesses deep expertise in electromagnetic design, finite element analysis (FEA), magnetic circuit optimization, motor performance modeling, and multidisciplinary product development.

As a technical leader, this individual will collaborate closely with Mechanical Engineering, Manufacturing Engineering, Quality, Program Management, and Sales teams to deliver innovative products that achieve industry-leading performance, reliability, and SWaP (Size, Weight, and Power) objectives.

General Responsibilities

• Advises on the creation of designs within inter-disciplinary teams to address complex product design and manufacturing challenges
• Leads feasibility studies and testing on new and modified designs
• Advises on development testing, engineering analysis, qualification testing, production launch
• Leads 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

Electromagnetic Design & Analysis

• Lead the electromagnetic design and development of BLDC motors, voice coil actuators, torque motors, and other custom electromechanical devices.
• Design stators, rotors, windings, magnetic circuits, and permanent magnet topologies to meet performance requirements.
• Develop motor architectures optimized for torque density, efficiency, dynamic response, thermal performance, and reliability.

Advanced Modeling & Simulation

• Utilize electromagnetic analysis tools such as ANSYS Maxwell, JMAG, MotorCAD, Flux, COMSOL, or equivalent simulation platforms
• Evaluate various magnet materials, winding schemes, lamination materials, and motor topologies.

Product Development & Innovation

• Lead development of next-generation motion-control products.
• Translate customer requirements into optimized electromagnetic designs.
• Support technology roadmaps and advanced research initiatives.

Cross-Functional Engineering Leadership

• Partner closely with Mechanical, Electronics, Manufacturing, and Program Management teams throughout the product lifecycle.
• Participate in design reviews, risk assessments, and technical decision-making.
• Provide Design for Manufacturability (DFM) and Design for Assembly (DFA) guidance.

Customer & Technical Support

• Interface directly with aerospace and defense customers on technical requirements, design reviews, and development programs.
• Support proposal development, technical presentations, and customer-facing engineering discussions.
• Contribute to business capture efforts and new product opportunities.

Technical Mentorship

• Mentor junior engineers and provide technical leadership across engineering teams.
• Establish best practices and design standards for electromagnetic product development.

Additional Experience and Qualifications Preferred

• Minimum 8 years of experience designing BLDC motors, voice coil actuators, or related electromagnetic devices.
• Strong understanding of:
• Electromagnetic theory
• Permanent magnet motors
• Magnetic circuits
• Power conversion principles
• Thermal management
• Experience developing custom motors from concept through production.
• Knowledge of motor drive electronics and control systems.

Additional Requirements

This position may require eligibility to obtain authorization under the International Traffic in Arms Regulations (ITAR) and/or the Export Administration Regulations (EAR). Candidates must be legally authorized to work on applicable Aerospace & Defense programs.

Travel: Up to 15%

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Base Salary Range:

$147,120.00 - $202,290.00

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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