Senior Staff Mechanical Engineer – Aerospace Gearing

Key Responsibilities

• 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.
• 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.
• Lead supplier development and special process management.
• 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.

Quality Engineering & Inspection (Precision Components)

• 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.

Manufacturing & Technical Leadership

• 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.

Key Skills

• Effective written and verbal communication skills including presentations, (Customer, internal and management).
• Writes and communicates critical reports.
• Led complex design reviews, internally and Customer.
• Expert technical writing skills (procedures, reports, etc.).
• Cumptent 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.

Other Qualifications

• 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 long, slender components Precision assembly, preload setting, and end-of-line functional testing Lead accuracy, positioning error, backlash control, and preload optimization Friction, efficiency, and wear characteristics in high-load applications Lead measurement, travel variation analysis, preload verification, and torque-to-rotate testing Precision measurement techniques similar to gearing.