Staff Engineer, Mechanical (Actuation

Position: Staff Engineer, Mechanical (Actuation)

Location: Parsippany, NJ

Job : -NB

# of Openings: 1

Staff Mechanical Engineer (Actuation) will design, develop, test, qualify, and support the production of mechanical components and electromechanical actuators for aerospace & defense applications. The role is within a multi‑disciplined organization collaborating with manufacturing, purchasing and quality assurance when needed.

• Design Electromechanical Actuators from a blank sheet of paper to meet customer requirements.
• Design of spur, bevel, worm and planetary gears.
• Design and analysis of kinematic mechanisms i.e., slider‑crank, scotch‑yoke, 4‑bar.
• Sizing and selection of ball screws capable of meeting system performance requirements.
• Sizing and selection of bearings (radial, thrust, angular contact) to meet loads and life necessary to meet system performance.
• Familiar with brushless DC motor design.
• Create and modify drawings with appropriate GD&T, documentation of changes and verify BOM. Ensure accuracy of drawings.
• Design cost‑effective, easily manufacturable hardware taking into account:
  • tolerance stack‑ups
  • ease of assembly
  • customer installation requirements
  • materials of construction
  • methods of manufacture
  • mechanical environment (thermal and vibrational) and application loading
  • preliminary analytical results (hand‑calc & FEA)
  • mistake‑proofing
• Disposition non‑conforming hardware and correct production/vendor issues.
• Perform failure investigations of designs.
• Create, review and approve processes for assembly, test and related activities to the development and qualification testing of a design.
• Interface with internal and external customers to determine product changes needed for applications as a company representative.
• Write technical documents for internal and external customers.
• Participate in design reviews (internal and external).
• Support new business pursuits that address program technical requirements and associated schedule and costs.
• Mentor and guide junior team members.

• Bachelor’s degree in mechanical engineering.
• Experience designing and testing designs to Mil‑Std‑810 environments or similar (humidity, salt fog, vibration and shock, etc.).
• Excellent verbal and written communication skills.
• Experience solving technical problems using a methodical scientific approach.
• Experience in 3‑D modeling of mechanical components and assemblies preferably CREO.
• Experience with electromechanical actuation servo systems.
• Experience with brushless DC motor design and/or operation.
• Experience with finite element analysis for structural, thermal and dynamic analysis.
• Organizational and task‑management skills to handle concurrent issues in parallel.
• Leadership skills to interface with other teams and disciplines at the company.
• Knowledge of manufacturing processes such as additive manufacturing, casting, milling, turning, grinding, drilling, etc.
• Must be a US citizen and able to obtain and maintain a security clearance.
• Exposure to typical manufacturing/machine shop environments (fluids, fumes or airborne particles, moving mechanical parts, noise and vibration).
• Work in a professional office environment and a manufacturing/machine shop environment using standard office equipment (computers, phones, printers, scanners, copiers).
• Work environment may be affected by outside/external temperatures and machining processes.
• Some travel may be required (15 %).
• Full‑time position.

• Regular need to talk and hear.
• Frequent need to reach with hands and arms, and to use hands to finger, handle or feel.
• Specific vision requirements: close vision, distance vision, peripheral vision, depth perception and ability to adjust focus.
• Regular need to stand for long periods (7–8 hours daily), walk consistently, stoop, bend, turn, balance and/or crouch, and move about the facility.
• Ability to skillfully use measuring instruments, hand and power tools.
• Potential to lift, push, pull and/or move items weighing up to 50 pounds.

Pay Range: $137,000 to $150,000 per year

• Medical, prescription, dental, vision, life and disability insurance.
• 401(k) plan with company match.
• Tuition assistance.
• Paid vacation, sick and personal days, paid holidays.
• Flexible scheduling options such as compressed workweeks.