Micro BLDC Motor Development Engineer

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BLDC Motor Development Engineer

• Define motor architecture and specifications: torque/speed, efficiency, thermal limits, life, noise/vibration, and size constraints (4–8 mm OD).
• Select topology and configuration (slot/slotless, 2P/4P, coreless/iron core, winding style, magnet type, commutation approach).
• Design key components: 

  stator/lamination or coreless structure, windings, rotor, magnets, shaft, bearings/bushings, housing, endcaps, insulation and adhesives

  .
• Work with drive/control engineers to define commutation strategy, sensorless/sensored requirements, and interface constraints.

• Perform 

  electromagnetic simulation

   (back-EMF, torque constant, cogging, losses, inductance, saturation, demag margin).
• Perform 

  thermal modeling

   (steady-state and transient; winding/housing temperature rise; duty cycle analysis).
• Perform 

  mechanical analysis

  : rotor dynamics, critical speed, balance, shaft deflection, bearing loads, tolerances, and fit stack-ups.
• Conduct NVH and efficiency improvement iterations (loss breakdown, magnet/steel/winding optimization).

• Build and validate prototypes (in-house or with vendors).
• Set up and execute motor characterization: 

  Kt/Ke, no-load current, efficiency map, torque-speed curve, temperature rise, runout, vibration, acoustic noise

  .
• Conduct reliability testing: life/endurance, start-stop cycling, contamination sensitivity, shock/vibration, thermal cycling (as applicable).
• Root-cause failures and drive corrective design/manufacturing changes.

• Own DFM/DFA for micro-motor manufacturing: winding processes, magnet bonding, rotor assembly, bearing press, balancing, and QA.
• Define manufacturing process flow, jigs/fixtures, critical-to-quality (CTQ) parameters, and acceptance criteria.
• Work with vendors for 

  laminations, magnets, wire, adhesives, bearings, shafts, micro-machining, and assembly

  .
• Support pilot builds, yield improvement, process capability (Cp/Cpk), and transfer to stable production.

• Create and maintain design documents: drawings, tolerances, stack-up analyses, BOM, test plans, and validation reports.
• Support design reviews, risk assessments, and change control (ECR/ECO).
• Ensure compliance with relevant quality practices (ISO-style documentation discipline; medical-grade experience is a plus).

• B.E./M.E. in Mechanical / Electrical / Mechatronics (or equivalent).
• Proven experience designing 

  small BLDC motors

  ; 

  micro-motor experience (≤10 mm OD)

   is strongly preferred.
• Strong fundamentals in electromagnetics, motor design, and precision mechanical engineering.
• Hands-on experience with prototyping and motor testing/characterization.

• EM tools: 

  ANSYS Maxwell / Motor-CAD / JMAG / FEMM

   (or equivalent).
• Mechanical CAD: 

  SolidWorks / Creo / NX

  .
• Analysis: thermal/structural tools (ANSYS, etc.), tolerance stack-up methods.
• Manufacturing knowledge: micro-winding, magnet bonding, balancing, bearing fits, adhesives/insulation, QA metrology.

• Experience with medical devices, implantable/percutaneous systems, or high-reliability micro-actuation.
• Experience with encoder integration or micro position sensing (Hall/encoder).
• Experience working with motor controllers and closed-loop control constraints (even at a requirements level).
• Knowledge of sterilization constraints/material compatibility (if applicable).

• Freeze a baseline motor architecture for 4–8 mm OD platform.
• Deliver working prototypes meeting key torque/speed/efficiency targets.
• Establish repeatable assembly/testing process and vendor pipeline.
• Identify top 3–5 design/manufacturing risks and mitigate with clear action plans.