Senior Manufacturing Engineer - Motor Windings at Blue Origin in Longmont, CO

Job description

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 c