Senior Mechanical Engineer

Location: Whippany, NJ (Onsite)

Our Client, a leading aerospace and defense manufacturer, is seeking a highly experienced Senior Mechanical (Design) Engineer to lead the design, development, qualification, and support of complex aerospace mechanical systems and products. This position requires a strong background in mechanical mechanisms, power transmission systems, qualification testing, and regulated aerospace product development
. The ideal candidate will have experience taking products through the complete lifecycle, from concept and requirements development through design, analysis, qualification testing, production, and aftermarket support within a highly regulated aerospace environment.

• Lead the design and development of complex mechanical systems and mechanisms, including:
  • Gear drives
  • Mechanical transmissions
  • Brakes
  • Clutches
  • Actuation systems
  • Electrical motors and control systems
• Develop products from:
  • Customer requirements
  • Concept development
  • Detailed design
  • Engineering analysis
  • Prototyping
  • Qualification testing
  • Production release
  • Sustaining engineering support
• Perform and support:
  • Stress analysis
  • Structural analysis
  • Mechanical analysis
  • Tolerance stack-up analysis
  • Reliability and safety analysis
• Create and maintain:
  • Engineering drawings
  • Test plans
  • Qualification procedures
  • Test reports
  • Design documentation
  • Manufacturing documentation
• Conduct and support qualification testing in accordance with:
  • MIL-STD-810
  • RTCA DO-160
  • Customer-specific aerospace standards
• Perform:
  • FMEA (Failure Modes and Effects Analysis)
  • Reliability analysis
  • Safety assessments
  • Root cause investigations
• Work closely with:
  • Manufacturing
  • Quality
  • Test engineering
  • Suppliers
  • Customers
  • Program management teams
• Support engineering change activity, configuration management, and product lifecycle management processes.

• Bachelor's degree in Mechanical Engineering or related engineering discipline.
• 10+ years of mechanical design engineering experience in:
  • Aerospace
  • Defense
  • Aviation
  • Other highly regulated industries
• Direct experience designing:
  • Mechanical gear drives
  • Gearboxes
  • Power transmission systems
  • Brakes
  • Clutches
  • Mechanical mechanisms
  • Actuation systems
• Experience with:
  • Electrical motors
  • Control systems
  • Hydraulic systems
• Strong experience with:
  • Qualification testing
  • Test planning
  • Test procedures
  • Test reports
• Hands-on experience with:
  • MIL-STD-810
  • DO-160 qualification testing
• Experience performing:
  • FMEA
  • Reliability analysis
  • Safety analysis
  • Root cause analysis
• Proficiency with:
  • GD&T
  • ASME Y14.5
• Strong experience using:
  • 3D CAD modeling software
  • CREO (preferred)
• Experience with:
  • Stress analysis
  • FEA
  • Engineering calculations
• Familiarity with:
  • AS9100
  • ISO 9001
  • Aerospace quality systems

• Experience with aerospace rescue, lifting, actuation, hoisting, winch, or transmission systems.
• Experience with electro-mechanical products.
• Experience with hydraulic or pneumatic systems.
• Background supporting military, commercial aerospace, or FAA-regulated products.
• Project leadership or program management experience.

The Successful Candidate Will Have a Combination Of

• Aerospace mechanical design expertise
• Gear drive and mechanism design experience
• Qualification testing experience (MIL-STD-810 / DO-160)
• FMEA, safety, and reliability analysis capabilities
• Strong CAD/CREO skills
• GD&T / ASME Y14.5 proficiency
• Hands-on product development experience from concept through production in a highly regulated environment.