Senior Mechanical Design Engineer

Modal Motors; Farmington Hills (MI); On-site; USD 120,000 - 160,000; Full time

Benefits offered by this job

Paid time off

Job summary

Modal Motors, Inc. is a startup advancing next-generation claw pole transverse flux DC motor systems for mobility and robotics. We seek a Senior Mechanical Design Engineer to own complex mechanical and electromechanical assemblies from concept through validation and production readiness.

You will lead projects, mentor junior engineers, and ensure designs balance performance, reliability, cost, and schedule while coordinating with multiple disciplines and suppliers.

Qualifications

• 10+ years in mechanical design or product development for complex assemblies.
• Experience leading projects from concept to production release.
• Proficiency in 3D CAD and detailed drawings with GD&T.
• Experience with structural and thermal FEA.

Responsibilities

• Lead mechanical development projects with clear scope, milestones, and risks.
• Develop motor architectures and assemblies including housings, shafts, and thermal features.
• Create and review 3D CAD models and drawings with GD&T.
• Perform FEA and validate results with tests and calculations.
• Coordinate with multidisciplinary teams and suppliers to meet requirements.

Skills

10+ years exp

CAD design

GD&T

FEA

Education

Bachelor's degree

Tools

SolidWorks

CATIA

Job description

Advanced Technology Electric Motor Structures Development

Pay: Based on relevant experience and qualifications

Solve difficult engineering problems and see what you build become real. At Modal Motors, your designs don't wait in a queue. You will take housings, shafts, and thermal features from CAD to a prototype on the bench, test them, and help carry them into production.

COMPANY OVERVIEW

Modal Motors, Inc. is an advanced electric motor technology startup developing next-generation, high-efficiency Claw Pole Transverse Flux DC motor systems for mobility, robotics, and industrial applications. Our engineering team combines advanced modeling, rapid prototyping, and hands-on testing to develop practical solutions to complex electromechanical challenges.

POSITION SUMMARY

We are seeking a Senior Mechanical Design Engineer with a demonstrated ability to lead engineering projects and take ownership of complex mechanical and electromechanical assemblies from concept through validation and production readiness.

Reporting to the Director of Mechanical Engineering, you will lead assigned development projects while remaining directly involved in CAD design, analysis, prototype builds, and testing. You will translate requirements into manufacturable designs, coordinate work across disciplines and suppliers, mentor junior engineers, and make sound engineering decisions that balance performance, reliability, cost, and schedule.

KEY RESPONSIBILITIES

• Lead assigned mechanical development projects, defining scope, deliverables, milestones, resource needs, and technical risks; communicate progress and resolve issues that affect delivery.
• Develop and evaluate motor architectures, components, and assemblies, including housings, shafts, bearings, rotor and stator supports, and thermal management features.
• Create and review 3D CAD models, detailed drawings, geometric dimensioning and tolerancing (GD&T), and tolerance stack-ups using CATIA, SolidWorks, or compatible platforms.
• Perform structural and thermal finite element analysis (FEA), supported by engineering calculations and test results, to guide design decisions.
• Coordinate with electromagnetic, electrical, controls, and manufacturing engineers to resolve interfaces and achieve system requirements.
• Lead design reviews and assess failure modes, documenting technical decisions, corrective actions, and verification requirements.
• Work with suppliers on material and process selection, quotations, technical requirements, and design for manufacturability and assembly (DFM/DFA).
• Lead prototype assembly, dimensional inspection, troubleshooting, and root-cause analysis; use findings to improve subsequent designs.
• Develop validation plans with measurable acceptance criteria, oversee testing, and confirm that designs meet requirements before release.
• Maintain accurate bills of materials, engineering changes, revision control, and drawing release packages; mentor junior engineers and review their technical work.

REQUIRED QUALIFICATIONS

• 10+ years of experience in mechanical design or product development, including substantial responsibility for complex assemblies.
• Demonstrated success leading engineering projects from requirements and concept development through prototype testing and design release.
• Advanced proficiency in SolidWorks, CATIA, or comparable 3D CAD software, including assembly modeling and detailed engineering drawings.
• Practical experience with structural and thermal FEA, including selecting appropriate assumptions and boundary conditions and checking results against calculations or tests.
• Strong working knowledge of GD&T, tolerance analysis, material selection, precision fits, and manufacturing processes.
• Hands-on experience developing and troubleshooting electromechanical systems or rotating machinery.
• Ability to prioritize work independently, guide other engineers, coordinate suppliers, and communicate technical decisions and project risks clearly.
• Must be a US Citizen.

PREFERRED QUALIFICATIONS

• Bachelor's or master's degree in mechanical engineering or a related field. Equivalent relevant experience is valued; a degree is not required.
• Experience with electric motors, actuators, robotics, or other precision motion systems; familiarity with transverse flux or magnetic assemblies is a plus.
• Experience with ANSYS or comparable simulation tools, design failure mode and effects analysis (DFMEA), and product data management systems.
• Experience with machining, casting, stamping, laminations, powder metallurgy, or injection molding, and transitioning prototypes into repeatable production.

WORK ENVIRONMENT

This is an on-site position in Farmington Hills, Michigan, combining design work with prototype assembly and laboratory testing. Success requires initiative, practical judgment, and a collaborative approach in a startup environment with evolving priorities.

BENEFITS

• Paid time off

EQUAL EMPLOYMENT OPPORTUNITY

Modal Motors, Inc. is an Equal Opportunity Employer. Employment decisions are based on qualifications, merit, and business need. We do not discriminate on the basis of race (including traits historically associated with race, such as hair texture and protective hairstyles), color, religion, national origin, sex, pregnancy, sexual orientation, gender identity or expression, age, height, weight, marital status, familial status, disability, genetic information, protected veteran status, or any other characteristic protected by federal, state, or local law.

Modal Motors provides reasonable accommodations to qualified applicants with disabilities. If you need an accommodation at any point in the application or interview process, contact [e-mail].