Sr. Design Engineer - Electro-Mechanical Actuation

Work Model

You’ll work in a hybrid model, onsite at your designated Regal Rexnord location at least 3 days per week (Monday–Thursday), with flexibility to work remotely up to 2 days, including Friday.

This position will serve as technical lead and owner for Electro-Mechanical Actuation aerospace products. The engineer is responsible for the design, development, integration and validation of the actuator designs, including motor, gears, drive mechanisms, sensors and structural housings. The position works closely with customers and cross-functional engineering teams to deliver high-performance, flight‑critical actuation systems for next-generation aircraft platforms.

• Technical Leadership and System Design – Lead system architecture, sizing, and design of electro‑mechanical actuators (motor, gearing, ball screw/roller screw, position sensing). Perform analysis and design studies (torque‑speed, position accuracy, life, safety and reliability). Define and manage requirements flow‑down to the actuator component level.
• Product Development – Own actuator design through full lifecycle (concept → qualification → production). Lead design reviews (PDR, CDR) and ensure technical readiness. Develop and maintain engineering models, drawings, and specifications.
• Testing and Validation – Define and support component and system‑level test plans. Correlate analysis with test data and drive design improvements. Lead root cause investigations for test or field failures.
• Cross‑Functional Engineering Collaboration – Partner with component engineers, suppliers and manufacturing engineers to ensure proper integration. Provide technical oversight to suppliers. Drive DFM/DFA considerations and ensure producibility.
• Program Execution – Lead technical execution against program milestones and deliverables of numerous new product introductions. Balance performance, cost, weight, and manufacturability in design decisions. Support customer interactions with technical expertise. Assess and adapt to the impact of material availability, long‑lead components, and supplier delivery schedules on engineering development, build plans, and program milestones.
• Continuous Improvement – Assist in identifying & driving continuous improvement opportunities within the facilities and at our supplier’s locations. Contribute to the breakthrough product development process. Maintain and improve existing products. Create and maintain policies, procedures, engineering standards, programs, and work instructions.

• Requires a Bachelor’s degree in Mechanical Engineering or Aerospace Engineering or related discipline.
• 7+ years of EMA or related engineering work experience.
• Advanced knowledge in the application, design and theory of operations for electro‑mechanical actuators.
• Working knowledge of 3D Solid Modeling software such as Solid Works, Inventor, CREO, and/or CATIA.
• Advanced knowledge of engineering part drawings and Geometric Dimensioning and Tolerancing.
• Background in metal manufacturing environment including metal cutting and grinding.
• General working knowledge of the Production Part Approval Process (PPAP) and Advanced Product Quality Planning (APQP) tools.
• Knowledge of Stage‑Gate development processes.
• Experience working in a lean manufacturing or continuous improvement environment is required.
• Experience in root cause analysis and formal problem‑solving techniques.
• Demonstrated proficiency in time and project management.
• Strong customer service orientation / high level of interpersonal skills.
• Capable of occasional travel to customers and plants.

Expected base salary range: $83,500 – $130,000. Salary is dependent on a multitude of factors, including but not limited to the physical worksite location, the geographic market of that location, candidate’s skill set, level of experience, education and internal peer compensation comparisons among other potential factors.

• Medical, Dental, Vision and Prescription Drug Coverage
• Spending accounts (HSA, Health Care FSA and Dependent Care FSA)
• Paid Time Off and Holidays
• 401(k) Retirement Plan with Matching Employer Contributions
• Life and Accidental Death & Dismemberment (AD&D) Insurance
• Paid Leaves
• Tuition Assistance

Regal Rexnord is an Equal Opportunity and affirmative action employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex/gender, sexual orientation, gender identity, pregnancy, age, ancestry, national origin, genetic information, marital status, citizenship status (unless required by applicable law or government contract), disability or protected veteran status or any other status or characteristic protected by law.

Regal Rexnord is committed to a diverse and inclusive workforce.