Senior Electromechanical Systems Engineer

About Darkhive, LLC

Darkhive is making robotics accessible. Established in 2021, we are focused on the application of robotics in the public safety and defense communities. Our approach in accessibility is built on three pillars: low-cost, ease-of-use, and open interface design. 

With our autonomy software stack, military and public safety users intuitively interact with our robotics platforms which enable them to understand their environment and make decisions when it matters most.  Our palm-sized, autonomous drone demonstrates the capabilities of our integrated software and hardware solutions.

Darkhive is a growing group of U.S. Special Operations veterans, aerospace engineers, robotics perception experts, DevSecOps, defense technology executives, and superb support staff-above all, we are mission first team.  We believe that the U.S. and our allies around the world deserve high-quality, affordable tools that keep them safe when each second counts.

If you are a free-thinking problem solver who is looking for a highly collaborative and innovative environment, apply with Darkhive today!

We are looking for a Senior Electromechanical Systems Engineer to lead the design, analysis, and validation of custom brushless DC motors and electromechanical subsystems for drones, robotics, and next-generation mobility platforms. This is a hands-on engineering role that spans simulation, prototyping, performance testing, and design for manufacturability, with a focus on developing motors intended for mass production and high-volume manufacturing.

In addition to developing new motor architectures, you’ll conduct structured analysis of existing commercial motor systems to inform and refine in-house designs. You’ll collaborate across hardware, firmware, and manufacturing teams to ensure high efficiency, scalability, and performance in real-world applications.

This is an exempt, full-time role reporting to the VP of Engineering.  This position is hybrid with some work completed remotely and some work conducted from Darkhive’s headquarters in San Antonio, Texas.

Key Responsibilities

• Design, prototype, and validate brushless DC motors for use in drones and robotic platforms
• Conduct competitive analysis and performance characterization of off-the-shelf motor systems
• Simulate electromagnetic performance using tools like FEMM, Motor-CAD, JMAG, or ANSYS Maxwell
• Optimize stator/rotor geometries, winding schemes, magnetic material selection, and lamination stacks
• 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
• Collaborate on motor manufacturing process development, including winding, lamination, CNC housing, and rotor assembly
• Participate in hardware validation testing using lab instrumentation (dynamometers, scopes, thermal imaging, etc.)
• 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
• 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
  
  

Qualifications you bring:

·        Bachelor’s or Master’s degree in Electrical Engineering, Mechanical Engineering, Mechatronics, or a related field

·        Proven experience designing and simulating BLDC motors and electromechanical systems

·        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

·        Understanding of magnetic and structural materials used in motor design, including the role of ferromagnetic housings, conductive coatings (e.g., nickel, copper), and their effect on magnetic flux paths and thermal dissipation

·        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

·        U.S. Citizenship

Bonus Qualifications:

·        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

·        An active security clearance (this is not a requirement for the position).

Travel Requirements:

This role is eligible for remote or hybrid work; however, due to the hands-on nature of motor development, prototyping, and manufacturing process build-up, regular on-site work is required. The engineer will be expected to travel frequently to our facility in San Antonio, TX to support testing, validation, and coordination with the production team. Estimated travel is approximately 50%.

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.

·        Reasonable accommodations will be provided to any person with a disability to be able to perform the essential job functions of this position.

·        Darkhive retains the right to change or assign other duties as required for this position.

Selection Process:

·        Hiring team reviews applications

·        15 – minute pre-screen with Darkhive recruiter

·        30-minute phone screen with the hiring manager

·        Take home project

·        In-person or video interview with hiring team

Benefits Darkhive offers:

·        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

Darkhive is an equal-opportunity employer and prohibits discrimination and harassment against any employee or applicant because of race, color, gender (including pregnancy), age, gender identity, creed, religion, national origin, sexual orientation, marital status, genetic information, disability, political affiliation, protected veteran status, or any other status protected by federal, state, or local law.