Senior Motor Technology Development Engineer

Zipline•South San Francisco, CA

10h•$145,000 - $200,000

About The Position

Zipline is seeking a Senior Motor Development Engineer to develop next-generation electric motor technologies for its autonomous delivery systems. This hands-on mechanical engineering role focuses on turning new motor concepts, particularly stator winding concepts, into repeatable, production-ready processes. The engineer will work across design, manufacturing, test, controls, and supply chain to develop tooling, equipment, process methods, and technical documentation for reliable motor production at scale. Work spans early prototypes, process experimentation, equipment development, supplier engagement, and production readiness. The role calls for someone who can design fixtures, troubleshoot shop-floor processes, analyze build data, and work with suppliers to develop robust solutions. The position involves regular hands-on work in engineering labs, prototype build areas, and manufacturing environments, with occasional travel to suppliers or manufacturing partners for equipment builds, process trials, and production-readiness activities.

Requirements

Bachelor's degree in mechanical engineering, manufacturing engineering, mechatronics, or a related field.
At least 5 years of experience developing electromechanical products, manufacturing processes, or production equipment; senior-level experience is preferred.
Demonstrated experience taking a process or piece of equipment from concept through prototype, validation, and production release.
Strong hands-on mechanical skills and comfort working with tools, fixtures, prototype equipment, measurement systems, and production hardware.
Experience developing or improving manufacturing processes for motors, generators, actuators, or other electromagnetic components.
Practical knowledge of stator winding or coil manufacturing.
Ability to design and detail mechanical components and tooling using CAD, with working knowledge of tolerancing, GD&T, materials, and fabrication methods.
Experience with mechatronic equipment, including sensors, actuators, motion systems, pneumatics, basic electrical systems, and troubleshooting automated processes.
Experience with structured problem-solving, process capability analysis, DOE, measurement-system analysis, and statistical or data-driven process improvement.
Strong written and verbal communication skills and ability to work effectively with internal technical teams and external suppliers.
Willingness to spend significant time in labs, prototype areas, and manufacturing environments.

Nice To Haves

Experience with random-wound, concentrated, distributed, hairpin, or other winding architectures.
Experience designing or commissioning winding, coil-forming, wire-handling, insertion, stripping, crimping, welding, impregnation, or stator assembly equipment.
Experience with magnet wire, enamel insulation systems, slot liners, wedges, varnish or resin systems, lacing materials, and related motor manufacturing materials.
Experience developing automated or semi-automated equipment from a blank-sheet concept, including vendor selection and factory acceptance testing.
Familiarity with PLC-controlled machinery, industrial motion control, machine vision, force or torque monitoring, and production data collection.
Experience with motor electrical and mechanical validation, including winding resistance, hipot or insulation testing, surge testing, dimensional inspection, balancing, and functional testing.
Experience with design for manufacturing and assembly, PFMEA, process validation, capability studies, and production ramp-up.
Experience working with contract manufacturers, equipment integrators, or overseas suppliers.
Proficiency with CAD and drawing-release systems; experience with machining, sheet metal, additive manufacturing, or other rapid-prototyping methods.
Experience in aerospace, automotive, robotics, drones, or another high-performance electromechanical product environment.

Responsibilities

Lead development and industrialization of stator winding and other novel motor assembly processes, from early prototypes through production readiness.
Develop manufacturing methods for wire forming, winding, insertion, termination, impregnation, adhesive application, and related motor assembly operations.
Design, prototype, debug, and validate tooling, fixtures, gauges, and semi-automated or automated production equipment.
Translate motor design intent and performance requirements into manufacturable process specifications, equipment requirements, and acceptance criteria.
Plan and run hands-on experiments, design-of-experiments studies, and process trials to evaluate materials, tooling concepts, equipment architectures, and winding methods.
Build and test prototype motors and stators, and investigate defects and performance variation using structured root-cause methods.
Establish process windows, key process parameters, inspection methods, and test requirements for repeatable manufacturing.
Collaborate with electrical, electromagnetic, thermal, controls, test, quality, and operations engineers to resolve design-for-manufacturing and process integration issues.
Drive equipment and process development with external suppliers, including writing requirements, reviewing designs, managing build progress, supporting factory acceptance testing, and resolving technical issues.
Create and maintain manufacturing documentation, including process flows, work instructions, control plans, PFMEAs, equipment specifications, validation plans, and process qualification reports.
Evaluate manufacturability, scalability, cost, reliability, and production risk to support technology down-selects.
Transfer mature processes and equipment to manufacturing partners or internal production teams, and support ramp-up through capability improvement and corrective action.