Senior Electromechanical Systems Engineer

📍 Job Overview

• Job Title: Senior Electromechanical Systems Engineer
• Company: Darkhive
• Location: San Antonio, Texas, United States
• Job Type: Hybrid
• Category: Engineering - Electromechanical Systems
• Date Posted: 2025-06-18
• Experience Level: Mid-Senior level (5-10 years)
• Remote Status: Hybrid (some work completed remotely, some work conducted from San Antonio, Texas)

🚀 Role Summary

• Lead the design, analysis, and validation of custom brushless DC motors and electromechanical subsystems for drones and robotics.
• Collaborate across hardware, firmware, and manufacturing teams to ensure high efficiency and performance in real-world applications.
• Develop new motor architectures and conduct competitive analysis of existing commercial motor systems.
• Optimize stator/rotor geometries, winding schemes, magnetic material selection, and lamination stacks.
• Support the development and tuning of ESCs and motor control algorithms.
• Evaluate thermal behavior, torque/speed curves, back-EMF, and efficiency under dynamic load conditions.
• Participate in hardware validation testing using lab instrumentation.
• Work cross-functionally with embedded, mechanical, and RF teams on integration into system-level products.
• Create customer-facing documentation and provide support for motor integration and testing in customer applications.

📝 Enhancement Note: This role requires a strong background in electromechanical systems, motor physics, and manufacturing techniques. Familiarity with electromagnetic simulation tools and motor control algorithms is essential for success in this position.

💻 Primary Responsibilities

• Motor Design & Simulation: Design, prototype, and validate brushless DC motors for use in drones and robotic platforms. Simulate electromagnetic performance using tools like FEMM, Motor-CAD, JMAG, or ANSYS Maxwell.
• Motor Optimization: Optimize stator/rotor geometries, winding schemes, magnetic material selection, and lamination stacks to improve motor performance and efficiency.
• Motor Control & ESC Tuning: Support the development and tuning of ESCs and motor control algorithms, including FOC, trapezoidal, and sensorless methods. Evaluate thermal behavior, torque/speed curves, back-EMF, and efficiency under dynamic load conditions.
• Manufacturing Process Development: Collaborate on motor manufacturing process development, including winding, lamination, CNC housing, and rotor assembly. Participate in hardware validation testing using lab instrumentation.
• Cross-Functional Collaboration: Work cross-functionally with embedded, mechanical, and RF teams on integration into system-level products. Create customer-facing documentation and provide support for motor integration and testing in customer applications.
• Competitive Analysis: Conduct competitive analysis and performance characterization of off-the-shelf motor systems to inform and refine in-house designs.
• Documentation & Reporting: Document technical analysis, test reports, and design iterations to support product development and production scaling. Interface with suppliers and vendors during the motor development process, including coordination of prototype orders, responding to engineering inquiries, and sharing validation documentation.

📝 Enhancement Note: This role requires a hands-on approach to motor design, prototyping, and manufacturing process development. Strong communication skills and the ability to collaborate effectively with cross-functional teams are essential for success in this position.

🎓 Skills & Qualifications

Education: Bachelor’s or Master’s degree in Electrical Engineering, Mechanical Engineering, Mechatronics, or a related field.

Experience: Proven experience designing and simulating BLDC motors and electromechanical systems.

Required Skills:

• Proficiency with electromagnetic simulation tools (e.g., FEMM, JMAG, Motor-CAD, or similar)
• Deep understanding of motor physics, including torque generation, losses, back-EMF, and thermal effects
• Experience with motor manufacturing techniques, including laminated stators, precision winding, and rotor balancing
• Familiarity with ESCs and control strategies (FOC, sensorless, trapezoidal, PWM tuning), including tuning ESC parameters to optimize motor performance
• Knowledge of magnet selection, including material types (e.g., N52, N35, etc.), magnetic strength/grade, and geometric considerations for optimizing field strength and rotor dynamics
• Proficiency with CAD software such as SolidWorks or Autodesk Fusion 360 for designing mechanical components and assemblies
• Experience with vibration, resonance, and high-RPM balancing in rotating assemblies
• Strong hands-on skills with mechanical testing, prototyping, and lab instrumentation
• Proficiency using common electrical tools such as digital multimeters (DMMs), oscilloscopes, power analyzers, and other diagnostic equipment

Preferred Skills:

• Experience benchmarking and analyzing high-volume drone or UAV motors
• Background in linear actuator design or other electromechanical motion systems
• Familiarity with high-speed motor manufacturing equipment and processes
• Experience with ESC electrical design and testing, including use of ECAD tools such as Altium Designer, KiCad, or Eagle
• Experience with propeller selection and matching for performance testing and validation of BLDC motors
• U.S. Military Veteran status
• An active security clearance

Physical and/or Mental Requirements:

• Ability to sit and/or stand for periods of time
• Ability to use a keyboard, mouse, and other equipment with or without accommodations
• Ability to maintain awareness during business hours
• Ability to lift up to 15 pounds
• Excellent written and verbal communication and good command of the English language
• Learns and memorizes routine tasks

📊 Portfolio & Project Requirements

Portfolio Essentials:

• A portfolio showcasing previous motor design projects, including design iterations, simulation results, and performance test data
• Examples of collaborative work with cross-functional teams on motor integration and system-level products
• Documentation of motor manufacturing process development and hardware validation testing

Technical Documentation:

• Detailed technical reports on motor design, simulation, and performance testing
• Design specifications and requirements documents for custom brushless DC motors
• Customer-facing documentation and support materials for motor integration and testing in customer applications

💵 Compensation & Benefits

Salary Range: $120,000 - $160,000 per year (based on experience and location)

Benefits:

• Comprehensive medical plans; 2 plans are 100% employer paid insurance premiums
• 100% employer paid dental and vision insurance premiums
• Automatic 401k employer contribution with immediate vesting
• Unlimited vacation
• 11 Paid holidays
• 5 days of sick leave
• Stock options
• Welcoming and friendly work environment
• Respect of work-life balance

📝 Enhancement Note: The salary range provided is an estimate based on market research for similar roles in the San Antonio, Texas area. Actual salary may vary based on the candidate's experience and qualifications.

🎯 Team & Company Context

🏢 Company Culture

Industry: Darkhive is a robotics company focused on making robotics accessible to the public safety and defense communities. Their approach is built on three pillars: low-cost, ease-of-use, and open interface design.

Company Size: Darkhive is a growing group of U.S. Special Operations veterans, aerospace engineers, robotics perception experts, DevSecOps, defense technology executives, and superb support staff. They are a mission-first team that believes in providing high-quality, affordable tools that keep users safe when each second counts.

Founded: 2021

Team Structure:

• The electromechanical systems team consists of experienced engineers with expertise in motor design, simulation, and manufacturing processes.
• The team works closely with hardware, firmware, and manufacturing teams to ensure high efficiency and performance in real-world applications.
• Darkhive's flat organizational structure encourages cross-functional collaboration and innovation.

Development Methodology:

• Darkhive uses an agile development methodology, with a focus on continuous improvement and customer feedback.
• The team uses version control systems and collaborative development tools to ensure code quality and maintainability.
• Darkhive's development process emphasizes automated testing, code reviews, and regular deployment cycles to ensure high-quality products.

Company Website: Darkhive

📝 Enhancement Note: Darkhive's mission-first culture and focus on accessibility make it an attractive place for engineers who want to make a significant impact in the robotics industry.

📈 Career & Growth Analysis

Electromechanical Systems Engineer Career Level: This role is at the senior level, with a focus on leading the design, analysis, and validation of custom brushless DC motors and electromechanical subsystems. The ideal candidate will have a deep understanding of motor physics, manufacturing techniques, and electromagnetic simulation tools.

Reporting Structure: This role reports directly to the VP of Engineering and works closely with hardware, firmware, and manufacturing teams. The ideal candidate will be able to collaborate effectively with cross-functional teams and provide technical leadership on motor design and integration projects.

Technical Impact: The senior electromechanical systems engineer will have a significant impact on the performance, efficiency, and reliability of Darkhive's robotics and drone platforms. Their work will directly influence the user experience and safety of the products in real-world applications.

Growth Opportunities:

• Technical Leadership: As Darkhive continues to grow, there will be opportunities for the senior electromechanical systems engineer to take on more technical leadership responsibilities, including mentoring junior engineers and leading projects that span multiple teams.
• Product Development: With Darkhive's focus on continuous innovation, there will be opportunities for the senior electromechanical systems engineer to work on cutting-edge motor technologies and contribute to the development of new products.
• Career Progression: As Darkhive expands its product offerings and enters new markets, there will be opportunities for the senior electromechanical systems engineer to take on more senior roles within the organization, such as technical director or chief engineer.

📝 Enhancement Note: Darkhive's fast-paced growth and focus on innovation provide numerous opportunities for career growth and technical development in the electromechanical systems engineering field.

🌐 Work Environment

Office Type: Darkhive's headquarters in San Antonio, Texas, is a collaborative workspace designed to foster innovation and cross-functional teamwork. The office features open-concept workspaces, state-of-the-art prototyping and testing equipment, and a dedicated lab for hardware validation and integration.

Office Location(s): Darkhive's headquarters is located in San Antonio, Texas. The company is also eligible for remote work, with some work completed remotely and some work conducted from the San Antonio, Texas headquarters.

Workspace Context:

• Collaboration: Darkhive's open-concept workspace encourages cross-functional collaboration and knowledge sharing between engineers, designers, and other team members.
• Prototyping & Testing: The dedicated lab for hardware validation and integration allows engineers to test and iterate on motor designs quickly and efficiently.
• Cross-Functional Interaction: Darkhive's flat organizational structure and emphasis on cross-functional collaboration ensure that engineers have regular opportunities to interact with designers, marketers, and other stakeholders.

Work Schedule: Darkhive offers a flexible work schedule, with some work completed remotely and some work conducted from the San Antonio, Texas headquarters. The work schedule is designed to balance the needs of the business with the personal and professional development of each employee.

📝 Enhancement Note: Darkhive's collaborative work environment and emphasis on cross-functional teamwork make it an ideal place for engineers who thrive in dynamic, innovative settings.

📄 Application & Technical Interview Process

Interview Process:

1. Hiring Team Review: The hiring team reviews applications and selects candidates for a 15-minute pre-screen with a Darkhive recruiter.
2. Phone Screen: Candidates who pass the pre-screen are invited for a 30-minute phone screen with the hiring manager to discuss their qualifications and fit for the role.
3. Take-Home Project: Candidates who pass the phone screen are given a take-home project to demonstrate their technical skills and problem-solving abilities.
4. In-Person or Video Interview: Candidates who successfully complete the take-home project are invited for an in-person or video interview with the hiring team to discuss their project, technical skills, and cultural fit.

Portfolio Review Tips:

• Highlight previous motor design projects that demonstrate your understanding of motor physics, simulation tools, and manufacturing techniques.
• Include examples of collaborative work with cross-functional teams on motor integration and system-level products.
• Showcase your ability to document technical analysis, test reports, and design iterations to support product development and production scaling.

Technical Challenge Preparation:

• Brush up on your knowledge of motor physics, including torque generation, losses, back-EMF, and thermal effects.
• Familiarize yourself with electromagnetic simulation tools and motor control algorithms.
• Prepare for questions on motor manufacturing techniques, including laminated stators, precision winding, and rotor balancing.
• Practice explaining your thought process and technical reasoning to demonstrate your ability to collaborate effectively with cross-functional teams.

ATS Keywords: Brushless DC Motors, Electromechanical Systems, Motor Physics, Electromagnetic Simulation Tools, Motor Control Algorithms, Motor Manufacturing Techniques, Laminated Stators, Precision Winding, Rotor Balancing, Cross-Functional Teamwork, Technical Documentation, Hardware Validation Testing, Lab Instrumentation, Electrical Tools, Digital Multimeters, Oscillopes, Power Analyzers, Diagnostic Equipment, U.S. Citizenship, U.S. Military Veteran, Security Clearance.

📝 Enhancement Note: Darkhive's interview process is designed to assess the technical skills and cultural fit of candidates for the senior electromechanical systems engineer role. The take-home project and in-person or video interview provide opportunities for candidates to demonstrate their problem-solving abilities and technical expertise.

🛠 Technology Stack & Web Infrastructure

Motor Design & Simulation Tools:

• FEMM
• Motor-CAD
• JMAG
• ANSYS Maxwell
• SolidWorks or Autodesk Fusion 360

Motor Control & ESC Tuning:

• FOC (Field-Oriented Control)
• Trapezoidal control
• Sensorless control
• PWM (Pulse Width Modulation) tuning
• ECAD tools (Altium Designer, KiCad, Eagle)

Lab Instrumentation & Electrical Tools:

• Digital multimeters (DMMs)
• Oscilloscopes
• Power analyzers
• Thermal imaging cameras
• Dynamometers
• Other diagnostic equipment

Manufacturing Processes:

• Winding
• Lamination
• CNC housing
• Rotor assembly

📝 Enhancement Note: Darkhive's technology stack includes industry-standard tools for motor design, simulation, control, and manufacturing. The ideal candidate will have experience with these tools and a deep understanding of motor physics and manufacturing techniques.

👥 Team Culture & Values

Electromechanical Systems Engineering Values:

• Mission-Focused: Darkhive is a mission-first company that prioritizes the safety and well-being of its users above all else. The ideal candidate will be passionate about using their technical skills to make a positive impact in the public safety and defense communities.
• Innovative: Darkhive is committed to continuous innovation and pushing the boundaries of what is possible in the robotics industry. The ideal candidate will be curious, creative, and eager to take on new challenges.
• Collaborative: Darkhive's flat organizational structure and emphasis on cross-functional teamwork ensure that engineers have regular opportunities to interact with designers, marketers, and other stakeholders. The ideal candidate will be a strong communicator who thrives in dynamic, collaborative environments.
• Customer-Centric: Darkhive is committed to providing high-quality, affordable tools that meet the needs of its customers. The ideal candidate will be customer-focused and dedicated to ensuring that Darkhive's products exceed customer expectations.

Collaboration Style:

• Cross-Functional Integration: Darkhive's flat organizational structure encourages cross-functional collaboration and knowledge sharing between engineers, designers, and other team members.
• Code Review Culture: Darkhive emphasizes code reviews and peer programming practices to ensure high-quality, maintainable code.
• Knowledge Sharing: Darkhive fosters a culture of continuous learning and knowledge sharing, with regular opportunities for engineers to present on their work and share their expertise with the team.

📝 Enhancement Note: Darkhive's mission-focused culture, emphasis on innovation, and commitment to collaboration make it an attractive place for engineers who want to make a significant impact in the robotics industry.

🌟 Challenges & Growth Opportunities

Technical Challenges:

• Motor Design & Optimization: Develop new motor architectures that meet the performance, efficiency, and cost requirements of Darkhive's robotics and drone platforms.
• Competitive Analysis: Conduct structured analysis of existing commercial motor systems to inform and refine in-house designs.
• Thermal Management: Design and implement thermal management strategies to ensure the reliability and performance of Darkhive's motors in real-world applications.
• Vibration & Noise Control: Develop and implement strategies to minimize vibration and noise in Darkhive's motors, ensuring quiet and stable operation in real-world applications.

Learning & Development Opportunities:

• Technical Skill Development: Darkhive offers opportunities for engineers to develop their technical skills in motor design, simulation, control, and manufacturing.
• Career Progression: As Darkhive continues to grow, there will be opportunities for engineers to take on more senior roles within the organization, such as technical director or chief engineer.
• Conference Attendance & Certification: Darkhive encourages engineers to attend industry conferences and pursue relevant certifications to stay up-to-date with the latest developments in the robotics and electromechanical systems fields.

📝 Enhancement Note: Darkhive's fast-paced growth and commitment to innovation provide numerous opportunities for engineers to develop their technical skills and advance their careers in the electromechanical systems engineering field.

💡 Interview Preparation

Technical Questions:

• Motor Physics: Describe the principles of torque generation, losses, back-EMF, and thermal effects in brushless DC motors. How do these principles influence motor design and optimization?
• Simulation Tools: How have you used electromagnetic simulation tools like FEMM, JMAG, Motor-CAD, or ANSYS Maxwell to design and optimize motors? What are the limitations of these tools, and how have you addressed them in your work?
• Motor Control & ESC Tuning: How have you tuned ESCs and motor control algorithms to optimize motor performance? What are the trade-offs between different control strategies, and how have you balanced them in your work?
• Manufacturing Processes: Describe your experience with motor manufacturing techniques, including laminated stators, precision winding, and rotor balancing. How have you ensured the quality and consistency of motor manufacturing processes in your previous roles?

Company & Culture Questions:

• Mission-Focused: How do you approach mission-critical work, and what steps do you take to ensure the safety and well-being of users in your designs?
• Innovation: Describe a time when you pushed the boundaries of what was possible in your work. What challenges did you face, and how did you overcome them?
• Collaboration: How have you collaborated effectively with cross-functional teams in your previous roles? What steps do you take to ensure clear communication and alignment with stakeholders?
• Customer-Centric: How do you prioritize customer needs and feedback in your work? Describe a time when you went above and beyond to meet a customer's needs.

Portfolio Presentation Strategy:

• Motor Design Projects: Highlight previous motor design projects that demonstrate your understanding of motor physics, simulation tools, and manufacturing techniques.
• Collaborative Work: Showcase examples of collaborative work with cross-functional teams on motor integration and system-level products.
• Technical Documentation: Include detailed technical reports on motor design, simulation, and performance testing to demonstrate your ability to document technical analysis and support product development.
• Customer-Focused Projects: Highlight projects that demonstrate your commitment to customer-centric design and your ability to prioritize customer needs and feedback in your work.

📝 Enhancement Note: Darkhive's interview process is designed to assess the technical skills and cultural fit of candidates for the senior electromechanical systems engineer role. The technical questions, company and culture questions, and portfolio presentation strategy provide opportunities for candidates to demonstrate their problem-solving abilities and technical expertise.

📌 Application Steps

To apply for this senior electromechanical systems engineer position at Darkhive:

1. Review the Job Description: Carefully read the job description and ensure that you meet the qualifications and experience requirements for the role.
2. Tailor Your Resume: Customize your resume to highlight your relevant experience, skills, and accomplishments in electromechanical systems engineering, motor design, and simulation.
3. Prepare Your Portfolio: Curate a portfolio that showcases your previous motor design projects, collaborative work with cross-functional teams, and technical documentation to support product development and production scaling.
4. Practice Technical Interview Questions: Brush up on your knowledge of motor physics, simulation tools, and manufacturing techniques. Practice answering technical interview questions to demonstrate your problem-solving abilities and technical expertise.
5. Research Darkhive: Learn about Darkhive's mission, values, and company culture. Prepare for company-specific questions and be ready to discuss how your skills and experience align with Darkhive's commitment to innovation, collaboration, and customer-centric design.
6. Submit Your Application: Apply through the application link provided in the job description. Include your resume, portfolio, and any other relevant documents that showcase your qualifications and fit for the role.

⚠️ Important Notice: This enhanced job description includes AI-generated insights and electromechanical systems engineering industry-standard assumptions. All details should be verified directly with Darkhive before making application decisions.