Senior Mechanical Engineer

Senior Mechanical (Design) Engineer - Aerospace / Defense

Location: Whippany, NJ (Onsite)

Position Overview

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.

Key Responsibilities

• 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.

Required Qualifications

• 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

Preferred Qualifications

• 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.

Ideal Candidate Profile

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.