Sr. Mechanical Engineer

Job Details

• Job Location:
  
  Chicago - Bedford Park, IL 60638
• Position Type:
  Full Time
• Education Level: College Graduate
• Salary Range: $ - $
• Job Shift: 1st Shift

Northstar Aerospace, now part of Avio Aero – a GE Aerospace Company, is a leading independent manufacturer of components and assemblies to the global Aerospace industry. Our principal products include gears and transmissions, accessory gearbox assemblies, rotorcraft drive systems, and other machined and fabricated parts for helicopters and fixed‑wing aircraft. We also provide maintenance, repair, and overhaul (MRO) on these platforms.

In this context we are reinforcing the focus to excellence in aeronautical mechanical transmissions (i.e. accessory drive‑train, power gearboxes and rotor drive systems) with an expansion of the Design Engineering team in the US offering distinctive solutions to our customers.

• Use experience and expertise to solve complex technical problems, lead design activities across part families, and contribute to both short‑term program goals and long‑term company objectives.
• Own the design definition and the technical integrity of the assigned mechanical components (focus on shafts, gear shafts, couplings and in general rotating components) within the New Product Introduction (NPI) process from concept design to product detailed definition, prototypes manufacturing/procurement, testing and certification.
• Create and update 3D models and 2D drawings using standard CAD tools while ensuring adherence to GE design standards, specifications, and regulatory requirements. Perform tolerance stack‑ups, geometric dimensioning and tolerancing (GD&T), and design for manufacturability (DFM) to ensure robust, producible designs.
• Support both new programs and legacy in‑service products, including quality note dispositions to ensure continuity of hardware deliveries.
• Guide Finite Element (FE) simulations to characterize component behavior and guide product definition in line with integrity, life, cost, weight and performance requirements.
• Contribute to strengthen the team’s technical capability in these areas.
• Apply knowledge of gearbox technical requirements, design processes, technologies, and materials for gear shaft and bearing applications.
• Define subsystem and component solutions, identify alternatives, and drive trade‑off studies.
• Discuss technical solutions with customers, supporting System Engineers in product definition (e.g. rotating components trade studies, bearing selections, risk assessments, etc.).
• Contribute to the preparation of Requests for Information (RFI) and Requests for Proposal (RFP) for customers.
• Define product architecture and components with applied technologies.
• Agree on and manage CTQs (Critical to Quality) and down‑select optimal design solutions to achieve performance, cost, weight, and reliability targets.
• Capture and flow‑down system‑level requirements to rotating components, including certification strategy and design specifications.
• Support the Sub‑Section Manager in coordinating internal and external design activities, such as defining system/product scope of work, preparing technical specifications, and assessing capabilities.
• Provide functional coordination and technical leadership to peers working on the same part‑family.
• Extend contributions across the product lifecycle, including advanced technology development and service/support phases when needed.
• Provide technical leadership in design reviews, substantiating and endorsing proposed design solutions.
• Work closely with an extended team, based in both Italy and the United States, ensuring aligned and integrated execution of work‑scopes.
• Travel up to 50% (domestic and international).

• Bachelor’s degree from an accredited university or college.
• Minimum of 3 years of experience with mechanical systems’ rotating parts (ideally gearbox technical requirements, design process and solutions, technologies, and materials for typical gears, gear shafts, bearings, and seals application).

• Master’s degree in Mechanical or Aeronautical Engineering from an accredited university or college.
• Experience with CAD…