Manufacturing Design Engineer

Regal Rexnord; West Chester (Chester County); On-site; USD 95,000 - 130,000; Full time

Job summary

Regal Rexnord is seeking an MD Engineer for Portescap’s Slotted Brushless DC motor line, onsite in our West Chester area facility. You will lead process development to move designs from prototype to production, partner with R&D for manufacturability, and advance tooling, fixtures, and equipment for preproduction readiness.

The role requires 3+ years in manufacturing/engineering, strong ISO quality system knowledge, and experience with Lean and Industry 4.0 initiatives.

Qualifications

• Bachelor’s degree in Mechanical Engineering or related field
• Minimum of 3 years in manufacturing/engineering roles
• Strong understanding of quality systems and ISO requirements
• AS9100 experience preferred
• Experience with Lean Manufacturing and Industry 4.0 initiatives preferred
• Export control compliance experience required

Responsibilities

• Partner with design engineers to ensure DFM and Assembly during concept and prototype phases
• Support prototype build and lead preproduction builds to identify manufacturability risks and implement countermeasures
• Lead manufacturing process development for new brushless DC motor products including tooling, fixtures, and process documentation
• Implement PPAP and production readiness documentation (flow charts, control plans, PFMEAs)
• Collect and analyze build data to improve process capability, quality, safety, and productivity
• Support ramp-up through troubleshooting, problem solving, and cross-functional communication
• Identify automation and Industry 4.0 opportunities to enhance data visibility and efficiency
• Support export‑controlled projects by complying with export control requirements

Skills

DFM

Project management

CAD modeling

Data analysis

Machine vision

Industry 4.0

Cross-functional

Problem solving

Education

B.S. Mechanical Engineering

Tools

CAD tools

CMMs

3D printing

Automation tooling

Job description

Work Model: This is a fully onsite role, with work performed at your designated Regal Rexnord office.

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The Manufacturing Design (MD) Engineer plays a key role in Portescap’s Slotted Brushless DC motor product line, supporting applications in surgical hand tools, surgical robotics systems, aerospace, defense-related programs, and other industrial markets. This position leads manufacture process development to transition prototype motor designs into final production, including projects that may be subject to International Traffic in Arms Regulations (ITAR). The role partners with R&D design engineers to assess manufacturability and supports prototype builds. It also develops process flows and standard work documentation, leads the design and validation of new product tooling, fixtures, and equipment for successful preproduction execution.

Essential Duties And Responsibilities

• Partner with design engineer team to ensure Design for Manufacturability and Assembly during concept and prototype phases.
• Support prototype build and lead preproduction builds to identify manufacturability risks, resolve build issues, and implement effective countermeasures prior to production release.
• Lead manufacturing process development for new brushless DC motor products, including the development, validation, and release of manufacturing tooling, fixtures, equipment, process flows, standard work, cycle‑time estimates, production investment plans, training materials, and operator coaching needed for production readiness.
• Implement PPAP and production readiness documentation, including manufacturing flow charts, control plans, PFMEAs, validation plans, and other ISO/AS9100/RBS required process controls.
• Collect, organize, and analyze build data, rolled-throughput‑yield performance, and operator feedback to improve process capability, quality, safety, and manufacturing performance.
• Support manufacturing ramp‑up through troubleshooting, structured problem solving, timely action‑plan execution, and cross‑functional communication.
• Identify and implement automation, smart manufacturing, machine vision, and Industry 4.0 opportunities to improve productivity, process monitoring, data visibility, quality, and safety.
• Support Export‑controlled projects by following applicable export control requirements, controlled work instructions, access controls, and documentation practices.
• Champion Regal Rexnord’s culture and core values: Integrity, Responsibility, Diversity, Engagement & Inclusion, Customer Success, Innovation with Purpose, Continuous Improvement, Performance, and Passion to Win, all with a sense of urgency.

Critical Competencies

• Strong sense of urgency, ownership, and results‑driven execution.
• Ability to collaborate effectively in cross‑functional manufacturing and engineering environments.
• Ability to use data analysis, design of experiments, and structured problem‑solving methods to make decisions and resolve issues.
• Demonstrated proficiency in time management, project management, prioritization, and follow‑through.
• Working knowledge of CAD modeling, tooling design, 3D printing and technical documentation.
• Familiarity with various manufacturing equipment and processes (laser welding, transfer molding) preferred
• Hand‑on experience with automation technologies, machine vision, and Industry 4.0 technologies, including data collection, equipment connectivity, process monitoring, and digital manufacturing tools.
• Familiarity with inspection and measurement tools, including CMMs, calipers, micrometers, and gages.
• Familiarity with electromechanical test equipment, including oscilloscopes, multimeters, and dynamometers.
• Strong written, verbal, computer, and technical documentation skills.

Education And Experience Requirements

• Bachelor’s degree in Mechanical Engineering, Industrial Engineering, Manufacturing Engineering, or a related technical field is required.
• Minimum of 3 years of manufacturing, manufacturing engineering, process development, or related engineering experience is required.
• Strong understanding of quality systems, ISO requirements, process improvement tools, and continuous improvement practices is required.
• AS9100 experience is preferred.
• Experience with Lean Manufacturing, structured problem solving, transfer molding, laser welding, tooling design, automation, machine vision, smart manufacturing, or Industry 4.0 initiatives is preferred.
• Ability to support export‑controlled projects and comply with applicable export control requirements is required.

Restrictions imposed by federal export control laws may limit this job opportunity to candidates who are a ‘U.S. Person,’ which includes U.S. citizens, U.S. nationals, U.S. permanent residents, individuals granted asylum in the United States, refugees in the United States, or individuals who otherwise qualify for a license permitting them to hold the position.

Benefits

• Medical, Dental, Vision and Prescription Drug Coverage
• Spending accounts (HSA, Health Care FSA and Dependent Care FSA)
• Paid Time Off and Holidays
• 401k Retirement Plan with Matching Employer Contributions
• Life and Accidental Death & Dismemberment (AD&D) Insurance
• Paid Leaves
• Tuition Assistance

About Regal Rexnord

Regal Rexnord is a publicly held global industrial manufacturer with 30,000 associates around the world who help create a better tomorrow by providing sustainable solutions that power, transmit and control motion. The Company’s electric motors and air moving subsystems provide the power to create motion. A portfolio of highly engineered power transmission components and subsystems efficiently transmits motion to power industrial applications. The Company’s automation offering, comprised of controls, actuators, drives, and precision motors, controls motion in applications ranging from factory automation to precision control in surgical tools.

The Company’s end markets benefit from meaningful secular demand tailwinds, and include factory automation, food & beverage, aerospace, medical, data center, warehouse, alternative energy, residential and commercial buildings, general industrial, construction, metals and mining, and agriculture.

Equal Employment Opportunity Statement

Regal Rexnord is an Equal Opportunity and Aff All qualified applicants will receive consideration for employment without regard to race, color, religion, sex/gender, sexual orientation, gender identity, pregnancy, age, ancestry, national origin, genetic information, marital status, citizenship status (unless required by the applicable law or government contract), disability or protected veteran status or any other status or characteristic protected by law. Regal Rexnord is committed to a diverse and inclusive workforce. We are committed to building a team that represents diverse and inclusive backgrounds, perspectives, and skills. If you’d like to view a copy of the company’s affirmative action plan for protected veterans/individuals with disabilities or policy statement, please email [e-mail]. If you have a disability and you believe you need a reasonable accommodation in order to search for a job opening or to submit an online application, please e‑mail [e-mail].

Equal Employment Opportunity Posters

Equal Employment Opportunity Posters