Senior Motor Mfg Development Engineer

Zipline is seeking a Senior Motor Development Engineer to develop next-generation electric motor technologies for its autonomous delivery systems. This hands-on mechanical engineering role focuses on turning new motor concepts, especially stator winding concepts, into repeatable, production-ready processes. The engineer will work across design, manufacturing, test, controls, and supply chain to develop tooling, equipment, process methods, and technical documentation needed to build motors reliably at scale. The role spans early prototypes, process experimentation, equipment development, supplier engagement, and production readiness.

Responsibilities

• Lead the development and industrialization of stator winding and other novel motor assembly processes for new motor technologies, from early prototypes through production readiness.
• Develop practical manufacturing methods for processes such as wire forming, winding, insertion, termination, impregnation, adhesive application, and related motor assembly operations.
• Design, prototype, debug, and validate tooling, fixtures, gauges, and semi-automated or automated production equipment.
• Translate motor design intent and performance requirements into manufacturable process specifications, equipment requirements, and acceptance criteria.
• Plan and execute hands-on experiments, design-of-experiments studies, and process trials to evaluate new materials, tooling concepts, equipment architectures, and winding methods.
• Build and test prototype motors and stators; investigate defects and performance variation using structured root-cause methods.
• Establish process windows, key process parameters, inspection methods, and test requirements that support repeatable manufacturing.
• Partner with electrical, electromagnetic, thermal, controls, test, quality, and operations engineers to resolve design-for-manufacturing and process integration issues.
• Drive equipment and process development with external suppliers, including writing requirements, reviewing designs, managing build progress, supporting factory acceptance testing, and closing technical issues.
• Create and maintain manufacturing documentation, including process flows, work instructions, control plans, PFMEAs, equipment specifications, validation plans, and process qualification reports.
• Support technology down-selects by evaluating manufacturability, scalability, cost, reliability, and production risk.
• Transfer mature processes and equipment to manufacturing partners or internal production teams, and support ramp-up through capability improvement and corrective action.

Requirements

• Bachelor's degree in mechanical engineering, manufacturing engineering, mechatronics, or a related field.
• 5+ years of experience developing electromechanical products, manufacturing processes, or production equipment; experience at the senior level is preferred.
• Demonstrated experience taking a process or piece of equipment from concept through prototype, validation, and production release.
• Strong hands-on mechanical skills and comfort working directly with tools, fixtures, prototype equipment, measurement systems, and production hardware.
• Experience developing or improving motor, generator, actuator, or other electromagnetic component manufacturing processes.
• Practical knowledge of stator winding or coil manufacturing. Experience with random-wound, concentrated, distributed, hairpin, or other winding architectures is valuable.
• Ability to design and detail mechanical components and tooling using CAD, with a working understanding of tolerancing, GD&T, materials, and fabrication methods.
• Experience with mechatronic equipment, including sensors, actuators, motion systems, pneumatics, basic electrical systems, and troubleshooting of automated processes.
• Experience using structured problem-solving methods, process capability analysis, DOE, measurement-system analysis, and statistical or data-driven process improvement.
• Strong written and verbal communication skills, with the ability to work effectively with both internal technical teams and external suppliers.
• Willingness to spend significant time in the lab, prototype area, and manufacturing environment.

Nice to have

• Experience designing or commissioning winding, coil-forming, wire-handling, insertion, stripping, crimping, welding, impregnation, or stator assembly equipment.
• Experience with magnet wire, enamel insulation systems, slot liners, wedges, varnish or resin systems, lacing materials, and related motor manufacturing materials.
• Experience developing automated or semi-automated equipment from a blank-sheet concept, including vendor selection and factory acceptance testing.
• Familiarity with PLC-controlled machinery, industrial motion control, machine vision, force or torque monitoring, and production data collection.
• Experience with motor electrical and mechanical validation, including winding resistance, hipot or insulation testing, surge testing, dimensional inspection, balancing, and functional testing.
• Experience with design for manufacturing and assembly, PFMEA, process validation, capability studies, and production ramp-up.
• Experience working with contract manufacturers, equipment integrators, or overseas suppliers.
• Proficiency with CAD and drawing-release systems; experience with machining, sheet metal, additive manufacturing, or other rapid-prototyping methods.
• Experience in aerospace, automotive, robotics, drones, or another high-performance electromechanical product environment.