Sr. Mechanical Engineer, Gearbox

Design, develop, and validate gearboxes and actuators

Design, develop, and validate plastic gears and gear trains for angle sensors and other mechatronic sensing/actuation applications

Perform gearbox design calculations, tolerance analysis, and tooth form optimization using KISSsoft

Specify and verify gear quality and tolerance requirements in accordance with Standard: ISO 1328

Apply plastic gear design guidelines per Standard: VDI 2736 accounting for shrinkage, thermal expansion, moisture absorption, and wear

Create detailed 3D models of plastic gears, gearboxes, shafts, etc.

Collaborate with electrical engineers to integrate gear trains with angle sensors and other position-sensing components

Coordinate injection-molded gear tooling, sampling, and validation efforts with Tier 1 and Tier 2 suppliers

Develop and execute design verification plans and reports (DVP&R) for gear performance, durability, and NVH

Lead and maintain design failure mode and effects analyses (DFMEAs) for gear and sensor assemblies

Prototype and iterate designs using hands-on fabrication, gear metrology, and lab testing to validate functionality

Proven experience designing plastic (injection-molded) gears, including tooth form compensation, backlash management, and material selection

Proficiency in KISSsoft for gear design, calculation, and simulation

Working knowledge of Standard: ISO 1328 gear tolerance classifications

Familiarity with Standard: VDI 2736 plastic gear design and testing guidelines

Experience designing gears for angle sensors or similar rotary position sensor gear trains

Proficient in 3D/2D CAD (Catia V5/V6 preferred) and Multibody dynamics (MBD)

Strong knowledge of GD&T and tolerance stack-up analysis

Solid foundation in polymer material properties, injection molding processes, and gear metrology

Familiarity with PLM systems, BOM structuring, engineering changes, and deviation processes