Manufacturing Engineer IV - Motor Windings

Blue Origin•Longmont, CO

10d•$123,611 - $173,055

About The Position

This role is part of Honeybee Robotics’ Motion Control Business Unit, which designs, manufactures, and tests high-performance motion control components and integrated solutions for commercial, defense, and space exploration missions. The Manufacturing Engineering Department ensures components and systems meet rigorous mission requirements. The Manufacturing Engineer specializing in motor windings owns the development, industrialization, and continuous improvement of manufacturing processes for motor winding and coil assemblies used in electric motors and actuators. The role leads new product integration, bringing winding designs from prototype into repeatable, scalable production, and applies high-volume manufacturing discipline in a high-mix, high-reliability aerospace environment. The engineer works alongside technicians and engineers to develop processes, tooling, and work instructions, provide hands-on production support, and resolve non-conformances.

Requirements

Bachelor of Science in Electrical Engineering, Mechanical Engineering, Manufacturing Engineering, Materials Science, Physics, or a related field, or equivalent experience.
At least 7 years of manufacturing engineering experience with electric motor, stator, rotor, or coil winding processes.
Demonstrated experience with new product introduction, including process development, validation, and transition from prototype to production.
Experience developing and using process control tools such as PFMEA, control plans, SPC, MSA, and DOE.
Experience operating, diagnosing, and dispositioning non-conforming electromechanical or electrical hardware.
Familiarity with standards such as IPC-A-610, IPC/WHMA-A-620, J-STD-001 with Space Addendum, NASA-STD-8739.4, and NEMA MW 1000, or equivalent automotive quality standards such as IATF 16949, PPAP, and APQP.
Proficiency in 3D CAD programs; SolidWorks or Creo Pro/E preferred.
Experience applying DFMA principles in design development.
Strong communication, organization, and project management skills, with the ability to manage multiple priorities.
Hands-on mindset, strong attention to detail, and ownership of work.
Ability to learn quickly in a fast-paced environment and adapt to new challenges.
Must be a U.S. citizen or national, U.S. permanent resident (current Green Card holder), or lawfully admitted into the U.S. as a refugee or granted asylum.

Nice To Haves

Experience in automotive or other high-volume manufacturing environments developing and producing motor winding products.
Hands-on experience with motor winding technologies and processes, including coil winding, slot liner and insulation system installation, lead termination, varnish/VPI, potting or encapsulation, and winding electrical testing.
Experience with aerospace, space, or defense motors and electromechanical actuators.
Experience with automated or semi-automated winding equipment, including programming, qualification, and process optimization.
Experience scaling motor winding processes from low-volume prototype to high-rate production.
Experience with hairpin or other advanced winding technologies used in traction or high-performance motors.
Experience with high-reliability or safety-critical hardware.
Experience automating inspection and testing of windings and motor assemblies.
Lean Six Sigma certification at Green Belt level or higher.
Experience with ERP/MES systems and electronic work instruction platforms.

Responsibilities

Lead new product integration for motor winding products, partnering with design engineering from concept through production release to ensure designs are manufacturable, scalable, and cost-effective.
Develop, validate, and document winding processes, including winding methods, coil forming, lead dressing and termination, lacing, insulation systems, varnish/VPI, potting, and bonding.
Define process parameters and process flows, and conduct process capability studies such as DOE, SPC, Cpk, and MSA.
Specify, design, and qualify winding equipment, fixtures, tooling, and ground support equipment, including semi-automated and automated solutions to improve quality, throughput, and yield.
Develop production documentation, including routings, work instructions, process control plans, and PFMEAs.
Define and implement in-process and end-of-line electrical test methods for windings, including resistance, inductance, insulation resistance, hipot, surge, and partial discharge testing.
Provide hands-on support to technicians to promptly resolve issues in production.
Lead troubleshooting and disposition of non-conforming winding and motor hardware through detailed work instructions.
Drive isolation, containment, and resolution of non-conforming parts and assemblies.
Lead root cause analysis and corrective actions to prevent recurrence of manufacturing and hardware issues.
Apply lean manufacturing and continuous improvement methods to reduce scrap, rework, and cycle time.
Support design and operational gated reviews by contributing technical artifacts and readiness assessments.
Collaborate with design engineering on Engineering Change Requests to improve manufacturability and reduce non-conformances.
Partner with design teams early in development to improve Design for Manufacture and Assembly before design release.
Work with suppliers on materials, magnet wire, insulation systems, and outsourced winding processes as needed.

Benefits

Medical insurance
Dental insurance
Vision insurance
Basic and supplemental life insurance
Paid parental leave
Short- and long-term disability
401(k) with company match of up to 5%
Education Support Program
Stock options for regular employees working at least 20 hours per week
Paid time off of up to four weeks per year based on weekly scheduled hours
Up to 14 company-paid holidays
Employees may be eligible for benefits and bonuses based on role type and job level; bonus amounts and eligibility are not guaranteed.