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GM Performance Power Units · 17 hours ago

MGU Mechanical Design Engineer

Concord, NC

Full-time

Onsite

Senior Level

5+ years exp

GM Performance Power Units is seeking a detail-oriented MGU E-Motor Mechanical Design Engineer to join their high-performance Formula 1 Energy Recovery System team. In this role, you will drive the mechanical design and development of the Motor Generator Unit e-motor, focusing on structural optimization and mechanical system reliability under extreme racing conditions.

AutomotiveElectric VehicleManufacturing

Responsibilities

Lead mechanical design of MGU components, including rotors, stators, bearings, housings, and thermal interfaces

Collaborate closely with the electromagnetic engineering team to optimize mechanical and electromagnetic integration for maximal motor performance and efficiency

Utilize machine learning (ML) techniques and Design of Experiments (DoE) to systematically explore design variables and optimize mechanical components

Develop designs controlling rotor dynamics to minimize eccentricity, vibration, and runout

Perform finite element and tolerance analyses to ensure structural integrity under high-speed operation

Support prototype development, testing, and data analysis including vibration and thermal monitoring

Collaborate with electrical, controls, and manufacturing teams to ensure seamless system integration

Manage design reviews, documentation, and compliance with Formula 1 technical regulations

Drive continuous innovation by researching new materials, fabrication technologies, and mechanical design methods for motorsport electric machines

Qualification

Mechanical Design Engineering3D CAD SoftwareFinite Element AnalysisRotor-Stator DynamicsVibration AnalysisPrototype TestingMachine LearningCollaborationProblem SolvingTime Management

Required

Bachelor's degree in Mechanical Engineering or related discipline with a minimum of 5 years of relevant mechanical design experience in high-speed electric motors or motorsport applications

Alternatively, Master's degree or PhD in Mechanical Engineering or related discipline with at least 2 years of demonstrated expertise in designing mechanical systems for electric machines or Formula 1 power units

Proficient in 3D CAD software (CATIA, NX, or SolidWorks) and finite element analysis tools

Strong understanding of rotor-stator dynamics, shaft alignment, and eccentricity mitigation techniques

Experience with precision bearing selection and integration (e.g., ceramic or hybrid bearings)

Skilled in vibration analysis, dynamic balancing, and tolerance stack-up methods

Hands-on experience with prototype testing, instrumentation, and performance data interpretation

Knowledge of Formula 1 hybrid power unit regulations is highly desirable

Experience or familiarity with machine learning methods for design optimization and application of Design of Experiments (DoE) to motor design problems is a plus

Preferred

Familiarity with F1 technical regulations, particularly those governing MGU components, rotor-stator integration, and power unit mechanical interfaces

Experience with CAE/FEA tools like ANSYS for thermal-structural simulations of high-speed e-motor rotors, stators, and bearing systems under F1 operating conditions

Hands-on experience in motorsport MGU prototyping, dynamometer testing, or cross-functional collaboration in hybrid ERS powertrains; preference for Formula SAE electric/hybrid powertrain participants

Knowledge of advanced materials (e.g., carbon composites, titanium alloys) and manufacturing processes like composite rotor housings, high-precision CNC rotor machining, and additive manufacturing

Knowledge of Design for Manufacture/Assembly (DFM/DFA) principles and tooling/jig design for MGU e-motor assembly and precision balancing fixtures

Experience conducting Failure Modes and Effects Analysis (FMEA) for high-speed rotating machinery and e-motor systems to identify and mitigate design risks

Understanding of engineering drawing standards (GD&T) and quality management systems for motorsport MGU components

Familiarity with PLM systems (e.g., Teamcenter) for MGU design version control