Sr. Mechanical Engineer, Gearbox

Job Details

Design, develop, and validate gearboxes and actuators
Design, develop, and validate plastic gears and gear trains for angle sensors and other mechatronic sensing/actuation applications
Perform gearbox design calculations, tolerance analysis, and tooth form optimization using KISSsoft
Specify and verify gear quality and tolerance requirements in accordance with Standard: ISO 1328
Apply plastic gear design guidelines per Standard: VDI 2736 accounting for shrinkage, thermal expansion, moisture absorption, and wear
Create detailed 3D models of plastic gears, gearboxes, shafts, etc.
Collaborate with electrical engineers to integrate gear trains with angle sensors and other position-sensing components
Coordinate injection-molded gear tooling, sampling, and validation efforts with Tier 1 and Tier 2 suppliers
Develop and execute design verification plans and reports (DVP&R) for gear performance, durability, and NVH
Lead and maintain design failure mode and effects analyses (DFMEAs) for gear and sensor assemblies
Prototype and iterate designs using hands-on fabrication, gear metrology, and lab testing to validate functionality

• Proven experience designing plastic (injection-molded) gears, including tooth form compensation, backlash management, and material selection

Proficiency in KISSsoft for gear design, calculation, and simulation
Working knowledge of Standard: ISO 1328 gear tolerance classifications
Familiarity with Standard: VDI 2736 plastic gear design and testing guidelines
Experience designing gears for angle sensors or similar rotary position sensor gear trains
Proficient in 3D/2D CAD (Catia V5/V6 preferred) and Multibody dynamics (MBD)
Strong knowledge of GD&T and tolerance stack-up analysis
Solid foundation in polymer material properties, injection molding processes, and gear metrology
Familiarity with PLM systems, BOM structuring, engineering changes, and deviation processes