MGU Mechanical Design Engineer

Job Title:

MGU E-Motor Mechanical Design Engineer

Location:

Concord, NC
Company: GM Performance Power Units (GM PPU)
Drive the Future of Formula 1 with GM PPU!

We’re seeking a detail-oriented MGU E-Motor Mechanical Design Engineer to join our high-performance Formula 1 Energy Recovery System (ERS) team located in Concord, NC. In this critical role, you will drive the mechanical design and development of the Motor Generator Unit (MGU) e-motor, focusing on structural optimization, rotor-stator integration, and mechanical system reliability under extreme racing conditions. You will create precise 3D models, detailed technical drawings, and run advanced simulations using state-of-the-art CAD and CAE tools to ensure performance and mechanical integrity of the MGU components.

You will collaborate closely with cross-disciplinary teams including electromagnetic engineers, electrical controls, thermal management, and manufacturing experts to optimize the mechanical‑electrical integration and packaging of the MGU within the hybrid powertrain. Adhering to stringent FIA technical regulations, you will participate in prototype reviews, testing and validation programs, and iterative design improvements to deliver highly reliable and performance‑driven mechanical solutions essential for competitive success.

• 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 motor sport electric machines.

• 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 motor sport 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 Solid Works) 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.

• 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 motor sport 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…