Senior Motor Design Engineer

Sensata Technologies, Inc.; Vista (CA); On-site; USD 130,000 - 190,000; Full time

Job summary

Sensata Technologies, Inc. in Vista, CA is seeking a Senior Motor Design Engineer to lead the electromagnetic design of BLDC motors, VCAs, and other precision motion-control devices for aerospace and defense applications.

You will collaborate with Mechanical, Electronics, Manufacturing, and Program Management teams to deliver high-performance, reliable products with optimized SWaP, mentor junior engineers, and drive design reviews, testing, and qualification activities.

Qualifications

• A university degree required (Bachelors) or equivalent work experience.
• Strong communication, organization and teamwork skills.
• Experience in electromagnetic design and multi-disciplinary development.

Responsibilities

• Lead electromagnetic design of BLDC motors, VCAs, and related devices.
• Develop stators/rotors and magnetic circuits to meet performance targets.
• Collaborate with Mechanical, Electronics, Manufacturing and PM teams.
• Support testing, qualification, and production launch activities.
• Mentor junior engineers and establish design standards.
• Interface with customers on requirements and technical discussions.

Skills

Electromagnetic design

Finite element analysis (FEA)

Magnetic circuit optimization

Motor performance modeling

Multidisciplinary product development

Communication skills

Team leadership

DFM / DFA guidance

Cross-functional collaboration

Education

Bachelor's degree

Tools

ANSYS Maxwell

JMAG

MotorCAD

Flux

COMSOL

Job description

Vista, CA

Full time

IRC98682

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