Principal Mechanical Engineer, Ball Screws

Principal Engineer for Ball Screw Design & Development

• Lead the design, development, and analysis of ball screw assemblies, including screw shafts, nuts, return systems, recirculation mechanisms, and drive interfaces.
• Define ball screw geometry, preload strategy, lead accuracy, life requirements, and lubrication approaches based on system needs and environmental constraints.
• Perform detailed analytical modeling: load distribution, Hertzian contact stress, fatigue life, torque prediction, friction modeling, stiffness and compliance, thermal effects, wear, and backlash behavior.
• Lead FEA/CAE activities involving nonlinear contact, dynamic loading, thermal–mechanical interactions, and structural optimization.
• Conduct advanced failure analyses (FMEA, root‑cause analysis) for wear, spalling, brinelling, lubrication breakdown, material defects, and contamination sensitivity.
• Define and validate material specifications, heat‑treat requirements, coatings/platings, cleanliness, and surface finish to achieve life and reliability targets.
• Collaborate closely with manufacturing engineering on grinding, thread‑rolling, grooving, nut machining, ball sizing, assembly sequencing, and quality control processes.
• Lead testing strategy including endurance testing, torque characterization, efficiency measurement, load testing, lubrication trials, and environmental qualification.
• Serve as technical lead or chief engineer for ball screw‑related programs, providing guidance to project engineers and designers.
• Partner with customers on requirements definition, performance trade studies, design reviews, and issue resolution.
• Drive continuous improvement and innovation in ball screw technologies, including new recirculation architectures, materials, and friction‑reduction methods.
• Ensure compliance with AS9100, aerospace design standards, traceability requirements, and export‑control regulations.
• Prepare and present high‑level technical reports, design justifications, risk analyses, and engineering review packages to internal leadership and customers.

• Bachelor’s degree in mechanical engineering or related discipline.
• 10+ years of experience in mechanical design, with at least 5 years specializing in ball screws, actuation systems, or precision motion components.
• Demonstrated expertise in contact mechanics, tribology, fatigue analysis, and precision mechanical design.
• Proficiency with 3D CAD and CAE tools (Solid Works, ANSYS, Abaqus, etc.).
• Strong understanding of aerospace/industrial product development life cycles.

• Deep knowledge of ball screw architecture, geometry optimization, preload techniques, and mechanical efficiency factors.
• Expertise in failure modes, reliability engineering, and life prediction specific to rolling‑element mechanisms.
• Ability to lead complex projects, mentor engineers, and influence technical direction.
• Excellent communication and customer‑facing skills, able to deliver complex technical material clearly.
• Strong capability in risk management, trade studies, and data‑driven decision making.

• Master’s or Ph.D. in Mechanical Engineering focused on tribology, contact mechanics, or machine design.
• Experience with electromechanical actuator systems.
• Background in high‑precision manufacturing or grinding/thread‑rolling process development.
• Experience with DO-160, MIL-STD environmental qualification, or similar aerospace standards.
• Six Sigma, DFSS, or advanced reliability engineering certification.

• Primarily office‑based engineering role with periodic hands‑on testing or lab work.
• Occasional travel to customers, suppliers, or test facilities.
• PPE may be required in some manufacturing or laboratory spaces.

This position must meet Export Control compliance requirements, therefore a “US Person” as defined by 22 C.F.R. § 120.15 is required. “US Person” includes US Citizen, lawful permanent resident, refugee, or asylee.