Senior Controls Engineer

LF Studios; Hazelwood (OH); On-site; USD 110,000 - 140,000; Full time

Job summary

LifeFormations, a leader in animatronics and themed entertainment design, seeks a Senior Controls Engineer to join our Cincinnati team. You will lead electrical engineering, motion control, and show-control system architecture, driving the development of reliable, maintainable automation for complex animatronic projects.

The role requires 7–10 years in controls or automation, strong multitier collaboration skills, and travel for installation and commissioning at domestic and international sites.

Qualifications

• Bachelor's degree in electrical engineering or related field is required.
• 7–10 years of professional controls engineering/automation experience.
• Strong knowledge of servo motion control and electrical power distribution.
• Experience designing and commissioning complex electromechanical systems.
• Willingness to travel domestically and internationally for installation and support.

Responsibilities

• Serve as senior technical authority for electrical engineering, motion control, and show-control systems.
• Lead development of complete controls architectures including power distribution and safety circuits.
• Design and implement multi-axis motion-control systems with servo motors and drives.
• Program, configure, and optimize control systems for precise motion.
• Lead FAT/SAT, diagnose complex issues, and document procedures.
• Collaborate with mechanical engineering, production, and project management teams.

Skills

Motion control

Electrical power

System integration

Leadership

Diagnostics

Education

Bachelor's degree in Electrical Engineering, Mechatronics, or related field

Tools

Weigl show-control systems

Elmo Motion Control

Harmonic Drive/IDT

Copley Controls

Job description

About the Job:

LifeFormations specializes in the design and fabrication of animated figures (animatronics), sculpted elements, exhibits, and interactive experiences. Our work can be found in leading theme parks, museums, science centers, and branded spaces all over the world. We are seeking a full-time Senior Controls Engineer to join our growing team in Cincinnati, Ohio.

The ideal candidate combines strong electrical engineering fundamentals with extensive hands-on experience in motion control, automation, and complex electromechanical systems. Experience in themed entertainment is highly desirable, but candidates from industrial automation, robotics, or other motion-control-intensive industries will also be considered.

Technical Leadership & Engineering:

• Serve as a senior technical authority for electrical engineering, motion control, and show-control systems.
• Lead the development of complete controls architectures, including power distribution, motor drives, safety circuits, communication networks, and animation playback systems.
• Independently evaluate technical requirements and develop reliable, maintainable solutions for complex animatronic and robotic applications.
• Establish and maintain electrical engineering standards, design practices, documentation requirements, and testing procedures.
• Provide technical guidance, mentorship, and oversight to controls engineers, technicians, and other production personnel.
• Collaborate with mechanical engineering, production, and project management teams to resolve complex integration challenges.

Controls Design & Programming:

• Design and implement sophisticated multi-axis motion-control systems utilizing servo motors, variable-frequency drives, pneumatic actuators, and other motion technologies.
• Develop and troubleshoot electrical schematics, control panels, wiring diagrams, and system documentation.
• Specify and integrate servo drives, motion controllers, PLCs, sensors, safety devices, and communication networks.
• Program, configure, and optimize control systems to achieve precise, repeatable, and synchronized motion.
• Integrate subsystem controllers with higher-level supervisory and attraction control systems.
• Evaluate emerging control technologies and recommend improvements to system performance, reliability, and maintainability.

System Integration & Commissioning:

• Take technical ownership of controls systems throughout design, fabrication, integration, testing, and commissioning.
• Lead factory acceptance testing (FAT), site acceptance testing (SAT), and system troubleshooting.
• Diagnose and resolve complex electrical, software, and motion-control issues.
• Support installation and commissioning activities at domestic and international project sites.
• Ensure compliance with applicable electrical codes, safety requirements, and client specifications.
• Develop technical documentation, commissioning procedures, and maintenance recommendations.

Required Qualifications:

• Minimum 7–10 years of professional experience in controls engineering, industrial automation, robotics, or related disciplines.
• Demonstrated experience independently designing and commissioning complex electromechanical control systems.
• Advanced knowledge of servo motion control, motor drives, electrical power distribution, and industrial control architectures.
• Strong understanding of electrical schematics, control panel design, circuit protection, and electrical safety.
• Proven ability to troubleshoot complex systems involving hardware, software, and mechanical interfaces.
• Experience leading technical projects and providing engineering guidance to other team members.
• Strong communication skills and the ability to interface directly with clients, vendors, and multidisciplinary engineering teams.
• Willingness to travel domestically and internationally for installation, commissioning, and technical support.
• Bachelor’s degree in electrical engineering, mechatronics, or a related discipline, or equivalent demonstrated professional experience.
• Applicants must be authorized to work in the United States without current or future employer sponsorship.

Preferred Qualifications:

• Experience with Weigl show-control systems and animation programming.
• Experience with Elmo Motion Control, Harmonic Drive/IDT, Copley Controls, or comparable servo-drive platforms.
• Experience integrating pneumatic, hydraulic, and electric motion systems.
• Familiarity with UL 508A and applicable machinery safety standards.
• Experience developing control systems for animatronics, themed entertainment, robotics, or other complex multi-axis motion applications.
• Experience integrating motion-control subsystems with supervisory PLCs or attraction control networks.
• Previous experience serving as a technical lead or senior engineering resource.