Engineering Consultant; Hypoid Gear Design

Engineering Consultant (Hypoid Gear Design)

We are seeking an experienced Hypoid Gear Design Consultant to provide expert technical guidance and hands‑on design support for driveline and differential programs. This consultant will advise engineering and manufacturing teams on hypoid gear geometry, contact pattern optimization, performance validation, and manufacturability—delivering solutions that balance performance, cost, and timing. The role is ideal for a seasoned gear design professional who thrives in a project‑based, advisory capacity.

• Serve as a subject‑matter expert for hypoid and spiral bevel gear design, analysis, and manufacturing readiness.
• Evaluate and refine existing gear designs for strength, durability, NVH, and efficiency improvements.
• Provide consulting on gear geometry definition (offsets, pressure angles, contact ratios) and system integration within axle or driveline assemblies.
• Review and validate supplier or OEM gear designs, providing design critiques and countermeasures to resolve performance or launch issues.
• Support root‑cause investigations of gear performance issues (noise, failure, wear, or contact pattern deviations).
• Develop and present technical reports, design reviews, and recommendations to client leadership and cross‑functional teams.
• Collaborate with internal and external teams to align on gear manufacturing feasibility, tooling constraints, and cost‑reduction opportunities.
• Support DFMEA, DVP&R, and tolerance stack analysis documentation where applicable.
• Mentor or train in‑house engineering staff on hypoid gear theory, software tools, and best practices.
• Gear geometry definitions, contact pattern simulations, and design validation results.
• Design recommendations with quantified impacts (e.g., torque capacity, noise reduction, cost savings).
• Technical documentation packages (design review decks, DFMEA/DVP&R inputs, tolerance analyses).
• Final summary report outlining design performance and implementation recommendations.

• Bachelor’s degree in Mechanical, Automotive, or Manufacturing Engineering (Master’s preferred).
• 10+ years of experience in gear system design, with a focus on hypoid or spiral bevel gearsets.
• Deep understanding of gear geometry, meshing theory, and contact pattern development.
• Proficiency with design and analysis tools such as GEMS, KIMoS, Hypoid 3D, Gleason software, or Romax.
• Working knowledge of CAD (NX, CATIA, or Solid Works) and CAE (FEA, durability, NVH) analysis methods.
• Proven track record supporting axle, driveline, or gearbox programs for OEM or Tier‑1 suppliers.
• Strong communication and presentation skills; able to deliver clear technical recommendations to both engineers and non‑technical stakeholders.