Design Engineer

JOB DESCRIPTION

Position Summary:  

The Mechanical Design Engineer is responsible for the mechanical design, development, and validation of 1/10–5 HP electric motors, including Induction Motors and EC Permanent Magnet Motors, for applications such as pool pumps, HVAC, laundry, food & beverage equipment, and other commercial products. The role covers end‑to‑end activities from 3D concept and detailed design through prototype build support, testing, and manufacturability improvement—working cross‑functionally with Electrical, Test Lab, Manufacturing, Quality, and Supply Chain to deliver robust, cost‑effective, and on‑time solutions.

Major Responsibilities:

-  3D Mechanical Design & Documentation

• Create high‑quality 3D models and complete 2D drawings (with GD&T) for housings, end bells, shafts, brackets, cooling fans/shrouds, terminals/boxes, sealing features, and mounting interfaces.
• Own engineering documentation: BOMs, specifications, tolerance stack‑ups, and design change records (ECN/ECR).

-  Motor Platform Development (Induction & EC PM)

• Translate performance targets (efficiency, torque, speed, NVH, thermal) into mechanical requirements and design features.
• Collaborate with Electrical/Controls teams on stack length, rotor design, cooling strategy, and packaging constraints.

-  Analysis & Validation

• Perform tolerance and fit analyses, basic structural/thermal assessments (and coordinate FEA where needed).
• Define mechanical test plans and support EVT/DVT prototype builds, including issue replication and root‑cause analysis.

-  Prototype & Manufacturing Support

• Work closely with Sample Build Technicians and Test Lab on assembly sequences, tooling/jigs, and measurement points.
• Drive DFM/DFS with suppliers and Manufacturing to optimize materials, processes (casting, machining, stamping, molding), and cost.

-  Quality, Compliance & Continuous Improvement

• Ensure designs meet safety and regulatory/industry requirements (e.g., UL/IEC scope as applicable) and customer specifications.
• Lead problem‑solving (8D/PDCA), implement corrective actions, and contribute to cost/VA‑VE activities.

-  Project Execution

• Plan deliverables and manage risk, tracking design actions against milestones from concept → prototype → pilot build → launch.
• Present design reviews and status updates to stakeholders and customers as required.

Required Education / Experience / Skills:

-  Bachelor’s or Master’s degree in Mechanical Engineering (or related).

-  3–7 years of relevant experience in mechanical design of rotating machinery, motors, pumps, or electromechanical products (open to strong junior profiles with demonstrated CAD excellence).

-  High proficiency in 3D CAD (e.g., SolidWorks, Creo, NX) and strong 2D detailing with GD&T; capable of clear manufacturing drawings.

-  Solid understanding of motor theory (fundamental to advanced): rotor/stator construction, magnetic air‑gap implications on mechanics, torque & losses impact on mechanical design, thermal paths/cooling, bearings & lubrication, sealing/IP concepts, and NVH basics.

- Hands‑on experience supporting prototypes and lab testing (assembly constraints, measurement methods, failure analysis).

-  Knowledge of materials & processes (Al/steel castings, sheet metal/stamping, machining, plastics molding) and surface treatments/coatings.

-  Experience with tolerance stack‑up, DFM, DFMEA, and BoM control.

-  Strong problem‑solving, data‑driven mindset; organized, detail‑oriented, and able to manage multiple projects.

-  Effective communication and teamwork with cross‑functional/global teams; comfortable presenting design reviews.

-  MS Office (Excel, Word, PowerPoint); exposure to PDM/PLM and ERP is a plus.

-  Nice to have (advantages): FEA basics (structural/thermal), CFD exposure for cooling/flow, understanding of UL/IEC requirements, customer‑facing development experience.

Travel

 Able to travel domestically/overseas as needed for supplier visits, customer reviews, or pilot builds.

Language:  Good English communication skill(written & spoken)

About Regal Rexnord