Electric Motor Design Engineer

About the role

You will join the e-drive team of an EV maker designing the electric machines at the heart of every vehicle. The team owns motor electromagnetic, thermal, and mechanical design from concept through production. This role matters because motor efficiency directly extends range, motor cost is a major line item, and your designs balance torque density, efficiency maps, NVH, and manufacturability in one of the most competitive engineering races in the industry. You will optimize electromagnetic designs trading torque density, efficiency map, and magnet cost, using FEA to squeeze every newton-meter from the active materials. Your thermal design will protect windings and magnets under repeated launch and fast-charge-adjacent duty cycles, validated with instrumented prototype testing. You will also work with manufacturing on hairpin winding and rotor assembly processes, because a brilliant design that cannot be built at volume is just a paper exercise.

What you will achieve

• Deliver motor designs achieving peak efficiency above 97 percent with torque density targets met and validated on dyno within 3 percent of simulation
• Cut motor active material cost by 10 percent through winding optimization, magnet grade selection, and lamination design
• Own electromagnetic, thermal, and structural co-design: no demagnetization, no thermal derate in rated duty, no NVH-critical resonances
• Drive manufacturing readiness: hairpin winding feasibility, rotor assembly processes, and supplier capability locked before design freeze
• Ship motors passing full DV schedules: thermal cycling, vibration, ingress, and 300k km equivalent durability with zero critical failures

What you will bring

Must-haves

• 2 to 5 years of experience designing electric machines (PMSM, induction, or wound-rotor) for automotive or industrial applications
• Strong electromagnetics fundamentals: flux paths, saturation, losses (copper, iron, magnet), and torque production
• Proficiency with JMAG, Ansys Maxwell, or Motor-CAD for electromagnetic and thermal analysis
• Understanding of motor control: FOC, MTPA/MTPV strategies, and their interaction with machine design
• Working knowledge of winding technologies: hairpin, distributed, concentrated, and their manufacturing implications
• Familiarity with rotor mechanical design: retaining sleeves, balancing, and high-speed structural integrity
• Experience with dyno testing: efficiency mapping, thermal testing, and NVH measurement

Nice-to-haves

• Experience with axial flux or other novel machine topologies
• Knowledge of magnet-free designs: synchronous reluctance or wound-rotor approaches
• Exposure to silicon carbide inverter co-design and switching frequency tradeoffs
• Understanding of rare-earth supply chains and magnet cost engineering