Senior Mechanical Engineer - Electromechanical Systems

Burlington, United States

We are seeking a hands-on Senior Mechanical Engineer to design and develop motors, actuators, gear-trains, and other high-reliability electromechanical products used in aerospace, defense, and industrial applications.

This is a true product design role with cradle-to-grave engineering ownership. You will be involved in everything from initial mechanical design and analysis through prototyping, qualification, production release, troubleshooting, and sustaining engineering.

The ideal candidate has direct experience designing electromechanical actuators, electric motors, gearboxes/gear trains, rotating equipment, or similar precision electromechanical products and understands how components such as gears, shafts, bearings, housings, seals, and mechanical interfaces work together as a complete system.

BS in Mechanical Engineering or related engineering discipline

5+ years of recent mechanical product design experience involving electromechanical actuators, motors, gear trains, rotating equipment, or comparable high-reliability products

Strong experience with geartrain/gearbox design, shafts, bearings, housings, and precision mechanical assemblies

Strong knowledge of tolerance stack-up analysis, GD&T, material selection, and design for manufacturability

Experience taking hardware from concept and detailed design through prototype, testing, qualification, and production

Hands-on experience troubleshooting prototype and production hardware

Experience performing or supporting structural/stress analysis

Ability to work closely with manufacturing, electrical engineering, quality, test, suppliers, and customers

U.S. Person required for export-control compliance

Experience designing electromechanical actuators or electric motor assemblies

Experience with BLDC/DC/AC motors, servo systems, or motion-control products

Experience with lubrication, sealing, FMEA, MTBF, and reliability analysis

DO-160 and/or MIL-STD-810 qualification experience

Experience with Autodesk Inventor, Autodesk Nastran, Ansys, Mathcad, or similar engineering tools

Experience supporting environmental and qualification testing

Design and develop mechanical components and assemblies for motors, actuators, gear trains, and related electromechanical products

Develop 3D CAD models, detailed drawings, specifications, BOMs, and complete engineering drawing packages

Design and evaluate gears, shafts, bearings, housings, interfaces, seals, and other precision mechanical components

Perform tolerance stack-ups, structural/stress analysis, material and finish selection, and component selection

Design for reliability, manufacturability, assembly, durability, and long-term product performance

Work with electrical engineers to integrate motors, sensors, feedback devices, electronics, and mechanical packaging into complete electromechanical systems

Support prototype builds, qualification and environmental testing, root-cause investigations, and design improvements

Troubleshoot mechanical and electromechanical issues involving prototype and production hardware

Support pilot builds, transition into manufacturing, sustaining engineering, and continuous product improvement

Work directly with manufacturing, quality, test, suppliers, customers, and other engineering disciplines to resolve technical issues and advance designs