Senior Mechanical Engineer – Aerospace Gearing

Advanced Gear Process Development & Industrialization

Lead end-to-end development of aerospace-qualified gear manufacturing processes development including spur, helical, bevel, and spline gears.

Define and document:

• Process flows, PFMEAs, control plans, and work instructions
• Key Characteristics (KCs) and Critical-to-Quality (CTQ) features
• Process capability requirements (Cp/ Cpk ) for critical gear geometry
• Work cooperatively with gearing designs to improve performance & manufacturability of new gearing products
• Develop and optimize machining processes including:
• Hobbing, shaping, skiving, broaching
• Profile and generating grinding
• Honing, lapping, and superfinishing
• Establish robust process control strategies for:
• Tooth profile accuracy, pitch variation, lead/helix error
• Surface finish, residual stress, and distortion control
• Define machining parameters, tooling strategies, and thermal controls to ensure repeatability in ultra-tight tolerance aerospace components.
• Lead process validation (IQ/OQ/PQ) and AS9102 First Article Inspection (FAI).
• Drive continuous improvement:
• Reduction of transmission error and gear noise
• Improved process capability and yield
• Implementation of advanced machining techniques and in-process monitoring

Serve as technical authority for gear manufacturing suppliers and special process providers.

Lead supplier qualification and audit activities to ensure compliance with:

• AS9100 quality systems
• Aerospace customer requirements
• Internal engineering specifications

Oversee and manage NADCAP-controlled special processes, including:

• Heat treatment (carburizing, nitriding, induction hardening)
• Shot peening and residual stress control
• Surface treatments (coatings, plating, corrosion protection)
• Non-destructive testing (MPI, FPI, ultrasonic)

Ensure detailed and accurate technical requirement flow-down, including:

• Gear macro- and microgeometry specifications
• Surface integrity and metallurgical requirements
• Full traceability and certification needs

Partner with suppliers on:

• Process capability improvement initiatives
• Root cause corrective action (RCCA, 8D)
• Monitor supplier performance via KPIs and support make vs. buy decisions.

Define and implement advanced inspection strategies for aerospace precision components, with emphasis on gearing.

Establish and validate measurement systems (MSA, Gage R&R) for:

• Gear profile, lead, pitch, runout, and composite error
• Surface finish, waviness, and microgeometry
• Utilize analytical inspection equipment (e.g., Klingelnberg, Gleason, Zeiss).

Ensure compliance with:

• AGMA, ISO, DIN, and aerospace standards
• Customer and regulatory requirements

Lead and support:

• AS9102 First Article Inspection (FAI)
• Internal, customer, and regulatory audits

Drive structured root cause investigations addressing:

• Transmission error and NVH performance issues
• Contact pattern deviations and load distribution
• Surface distress, wear, and fatigue

Implement SPC and continuous monitoring of critical characteristics.

Ensure full traceability, documentation, and configuration control for flight hardware.

Provide hands-on support to resolve complex machining and finishing issues on the shop floor.

Collaborate with design engineering on:

• Manufacturability (DFM)
• Tolerance stack-up and performance requirements

Mentor engineers and technicians in aerospace manufacturing best practices.

Interface cross-functionally with Design, Quality, Supply Chain, and Program Management.

• Effective written and verbal communication skills including presentations, (Customer, internal and management). Writes and communicates critical reports. Leads complex design reviews, internally and Customer. Expert technical writing skills (procedures, reports, etc.)
• Competent complex problem solving/troubleshooting skills for both components and subsystems.
• Promotes a cross-functional project team environment, communicates with Customers and leads small teams. May participate in setting technical direction/product strategies. Provides technical problems-solving guidance to others.
• Strong expertise in:
• Gear cutting and finishing processes
• Gear metrology and inspection
• GD&T and precision tolerancing
• Experience with:
• AS9100 quality systems
• AS9102 FAI requirements
• CNC and gear manufacturing equipment
• NADCAP special processes and supplier audits
• Familiarity with aerospace OEM requirements (Boeing, Airbus, etc.)
• Lean Six Sigma certification
• Advanced knowledge of gear analysis and inspection systems
• Background in tribology and gear system performance

• Bachelor's degree in a relevant field and 12+ years of applicable experience
• Certified Technician or equivalent technical certification
• Experience with precision ball screw manufacturing is preferred and adds value for aerospace actuation systems . Familiarity with the following would be great to have :
• Thread grinding, thread rolling, and whirling processes
• Heat treatment and distortion control of…