Job Description:
Sr. Motor Development Engineer
The Sr. Motor Development Engineer for RYOBI Outdoor Power Equipment is responsible for the mechanical design, development, and optimization of Brushless DC motors and Brushed PMDC motors to drive performance, efficiency, durability, and cost. This role emphasizes mechanical design excellence, manufacturing process knowledge, and cross-functional collaboration to deliver production-ready motor designs from concept through mass production.
Primary Responsibilities
- Lead mechanical design, development, prototyping, testing, and troubleshooting for high complexity projects.
- Develop detailed component drawings with appropriate GD&T, tolerances, and material specifications for motor components and sub-assemblies.
- Evaluate and select materials and manufacturing processes — including injection molding, die casting, stamping, and machining — to optimize cost, quality, and performance.
- Maintain a strong working knowledge of BLDC motor manufacturing processes such as stator lamination stamping, stator winding, magnet assembly, pressing operations, and testing methods.
- Interpret motor and power system performance curves (torque-speed, efficiency maps, thermal profiles) to draw conclusions about tool-level performance and inform design decisions.
- Drive hands-on evaluation and testing in outdoor power tools.
- Establish and drive motor test plans and mechanical verification strategies, including vibration, durability, thermal, and environmental testing.
- Conduct root cause analysis of mechanical test failures and drive corrective actions through design or process improvements.
- Collaborate with electrical and controls engineers to ensure motor mechanical designs are compatible with electronic drive systems and application requirements.
- Interface with motor component suppliers to review designs, resolve quality issues, and support sourcing of laminations, magnets, shafts, and other motor parts.
- Represent the motor development team in cross-functional project meetings and provide clear technical communication and project updates.
- Frame up and lead technical tradeoff discussions with product management and other cross functional teams that focus on Cost, Schedule, and Performance impact
Minimum Job Requirements
- Bachelor of Science in Mechanical Engineering or related field; advanced degree is a plus.
- 5+ years of experience in related design field.
- Strong mechanical design background with direct experience in injection molding, die casting, stamping, and machining processes.
- Familiarity with BLDC, Brushed PMDC, and AC motor design principles, motor topologies, and their application in power tools, outdoor equipment, or similar high-volume consumer products.
- Proficient with 3D CAD software and experienced with GD&T, tolerance analysis, and engineering drawings.
- Understanding of electronic systems and motor drive solutions as they relate to motor mechanical design and system integration.
- Understanding of motor assembly principles and motor component design/manufacturing and what drives cost and performance.
- Ability to travel 15% of the time (domestic and international).
We offer competitive wages and a comprehensive benefits package – tuition assistance, 401(k), medical/dental/vision coverage, vacation and holidays.
