Lead Engineer E-Motors
Lead Engineer E-Motors (Mechanical Design & Development) to support the development and validation of next-generation electric propulsion systems for a leading global electric vehicle manufacturer. The role involves mechanical design optimization, manufacturability assessment, supplier collaboration, structural and thermal simulations, test fixture development, and engineering release activities for e-Motor and associated propulsion components.
The ideal candidate will have extensive experience in electric motor mechanical design, CAE/CFD analysis, prototype development, and cross-functional engineering collaboration within the automotive industry.
Role and Responsibilities
Lead e-Motor mechanical design updates, optimization, and engineering change implementation.
Assess manufacturability, tolerance risks, and assembly feasibility in collaboration with suppliers.
Perform structural CAE and CFD simulations to validate durability and thermal performance.
Develop and modify motor housing, shafts, and test fixture components for prototype validation.
Create and release CAD models, engineering drawings, simulation reports, and technical documentation.
Support prototype build readiness, design reviews, and cross-functional engineering activities.
Collaborate with global engineering teams, suppliers, and testing groups to resolve design challenges.
Ensure compliance with quality, performance, and product development requirements.
Lead onsite coordination with customer engineering teams and act as the primary technical interface.
Plan, assign, and monitor engineering activities for offshore design and simulation teams.
Qualifications and Education Requirements
Bachelor's or Master's Degree in Mechanical Engineering, Automotive Engineering, Electrical Engineering, or related discipline.
Minimum 10 years of automotive product development experience, with significant exposure to electric propulsion systems.
Proven experience in E-Motor mechanical design and development.
Strong understanding of manufacturing processes, DFM/DFA principles, GD&T, tolerance analysis, and automotive standards.
Experience supporting prototype builds, testing, and validation programs.
Ability to work effectively in a global engineering environment with suppliers and cross-functional teams.
Preferred Skills
Expert proficiency in Catia V5/V6 for 3D modelling and drafting.
Experience with 3DX Enovia or equivalent product lifecycle management systems.
Strong CAE expertise using tools such as: ANSYS Mechanical, Abaqus, HyperWorks, Nastran
CFD simulation experience using: ANSYS Fluent, Star-CCM+, Converge or equivalent tools
Knowledge of electric motor architecture including:
- EESM (Electrically Excited Synchronous Motors)
- Permanent Magnet Motors
- Rotor and Stator assemblies
- Thermal management systems
- Motor housing and shaft systems
Pi-square technologies is a Michigan (USA) Headquartered Automotive Embedded Engineering Services company, Synergy Partner for major OEMs and Tier 1s and their implementation partners in Automotive Embedded Product Development, Projects, Requirements Analysis, Software Design, Software Implementation, Efficient Build, Release Process, and turnkey software V & V Services. We have more than 20+ years of industry expertise with specialization in the latest cutting-edge automotive technologies such as Infotainment, connected vehicles, Cyber security, OTA, and Advanced Safety/ Body electronics.
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