Senior Manufacturing Engineer - Motor Windings

Application close date:
Applications will be accepted on an ongoing basis until the requisition is closed.

At Blue Origin, we envision millions of people living and working in space for the benefit of Earth. We’re working to develop reusable, safe, and low-cost space vehicles and systems within a culture of safety, collaboration, and inclusion. Join our team of problem solvers as we add new chapters to the history of spaceflight!

As a member of the Blue Origin family of companies, Honeybee Robotics has been at the forefront of robotics for over 40 years. Our Colorado location specializes in creating advanced motion control solutions for NASA, defense, and commercial programs. Our work has played a critical role in thousands of projects, spanning from conceptual design studies to flight missions, including NASA's Artemis I Mission and the Roman Space Telescope. We are seeking technically brilliant individuals who are passionate about their work, thrive in collaborative environments, and have a laser focus on the details that drive excellence.

About the Role

This role is part of the Motion Control Business Unit at Honeybee Robotics, which designs, manufactures, and tests high-performance, reliable motion control components and integrated solutions that power the most demanding commercial, defense, and space exploration missions. From actuators and gearboxes to motors, motor controllers, and precision motion control systems, our products operate in the harshest environments, enabling critical missions from Earth to deep space. Our Manufacturing Engineering Department ensures every component and system meets the rigorous standards required for mission success.

As a Manufacturing Engineer IV specializing in motor windings, you will own the development, industrialization, and continuous improvement of manufacturing processes for motor winding and coil assemblies used in electric motors and actuators. You will lead new product integration (NPI) efforts, taking winding designs from prototype to repeatable, scalable production. You will bring high-volume manufacturing discipline, drawn from automotive or similar industries, to a high-mix, high-reliability aerospace environment. You will work alongside technicians and engineers to develop processes, tooling, and work instructions, support hands-on production, and resolve non-conformances.

Special Mentions

- Relocation provided
- Shift: Monday–Friday (5/8 schedule)
- Interviews will include a technical assessment

General Responsibilities include but are not limited to:

- 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 (e.g., needle, flyer, linear, or insertion winding, hairpin or form-wound coils, lead dressing and termination, lacing, insulation systems, varnish/VPI, potting, and bonding)
- Define process parameters, develop process flows, and perform process capability studies (e.g., DOE, SPC, Cpk, MSA) to establish robust, repeatable processes
- Specify, design, and qualify winding equipment, fixtures, tooling, and ground support equipment (GSE), including semi-automated and automated solutions that improve quality, throughput, and yield
- Develop comprehensive production process documentation, including routings, work instructions, process control plans, and PFMEAs
- Define and implement in-process and end-of-line electrical test methods for windings, such as resistance, inductance, insulation resistance, hipot, surge, and partial discharge testing
- Provide hands-on support to the technician team for prompt resolution of issues in a fast-paced production environment
- Lead troubleshooting and disposition of non-conforming (NC) winding and motor hardware through detailed work instructions
- Drive isolation, containment, and resolution of NC parts and assemblies
- Lead root cause analysis (RCA) and root cause corrective actions (RC/CA) 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 to required technical artifacts and readiness assessments
- Collaborate with design engineering to implement Engineering Change Requests (CRs) that improve manufacturability and reduce non-conformances
- Partner with design teams early in the development cycle to improve Design for Manufacture and Assembly (DFMA) prior to design release
- Work with suppliers on materials, magnet wire, insulation systems, and outsourced winding processes as needed

Minimum Qualifications

- Bachelor of Science in Electrical Engineering, Mechanical Engineering, Manufacturing Engineering, Materials Science, Physics, or a related field, or equivalent experience
- 7+ years of manufacturing engineering experience with electric motor, stator, rotor, or coil winding processes
- Demonstrated experience with new product introduction, including process development, process 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 industry standards such as IPC-A-610, IPC/WHMA-A-620, J-STD-001 with Space Addendum, NASA-STD-8739.4, and NEMA MW 1000 (magnet wire), or equivalent automotive quality standards (e.g., IATF 16949, PPAP, 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 with 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

Desired Qualifications

- Experience in automotive or other high-volume manufacturing environments developing and producing motor winding products
- Hands-on experience with motor winding technologies and associated processes, such as:

- Coil winding methods (needle, flyer, linear, insertion, or hairpin)
- Slot liner and insulation system installation
- Lead termination (soldering, welding, brazing, or crimping)
- Varnish, VPI, potting, or encapsulation
- Winding electrical testing (resistance, insulation resistance, hipot, surge)

- 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 test of windings and motor assemblies
- Lean Six Sigma certification (Green Belt or higher)
- Experience with ERP/MES systems and electronic work instruction platforms

Base Pay Range for:
CO applicants is $123,611.00 - $173,054.70

Other site ranges may differ

Culture Statement