Lead Aerospace Mechanical Design Engineer

W3Global; New Hanover Township (NJ); On-site; USD 120,000 - 170,000; Full time

Job summary

W3Global is seeking an experienced Senior Mechanical (Design) Engineer for aerospace/defense, onsite in Whippany, NJ. You will lead design, analysis, testing, and production release of complex mechanical systems and mechanisms, including gear drives, power transmission, braking, actuation, and related control systems.

The role requires 10+ years in regulated aerospace environments, strong GD&T/ASME Y14.5 skills, CREO CAD expertise, and hands-on qualification testing experience to support

Qualifications

• Bachelor's degree in Mechanical Engineering or related engineering discipline.
• 10+ years of mechanical design engineering experience in Aerospace, Defense, Aviation or other regulated industries.
• Direct experience designing gear drives, gearboxes, power transmission systems, brakes, clutches, mechanisms, actuators.
• Experience with electrical motors, control systems, hydraulics.
• Strong qualification testing, test planning, procedures, and reports experience.
• Hands-on MIL-STD-810 and DO-160 qualification testing experience.
• FMEA, reliability, safety, and root cause analysis capability.
• Proficiency with GD&T and ASME Y14.5.
• Extensive 3D CAD design using CREO or equivalent software.
• Stress/FEA, engineering calculations; familiarity with AS9100 and ISO 9001.

Responsibilities

• Lead design and development of complex aerospace mechanical systems and mechanisms.
• Develop products from customer requirements through concept, detailed design, testing and release.
• Perform stress, structural, mechanical, tolerance, reliability, and safety analyses.
• Create and maintain engineering drawings, test plans, qualification procedures and reports.
• Support qualification testing per MIL-STD-810 and DO-160; ensure compliance with aerospace standards.
• Conduct FMEA, reliability and safety analyses; root cause investigations.
• Collaborate with manufacturing, quality, test, suppliers, customers and program management.
• Support engineering change activity, configuration management, and PLM processes.

Skills

Mechanical design

Gear drives

Gearboxes

Power transmission systems

Brakes

Clutches

Actuation systems

Electrical motors

Control systems

Hydraulic systems

FMEA

Reliability analysis

Safety analysis

Root cause analysis

GD&T

ASME Y14.5

3D CAD modeling

CREO

Stress analysis

FEA

Engineering calculations

AS9100 knowledge

ISO 9001 knowledge

Aerospace quality systems

Education

Bachelor's degree in Mechanical Engineering

Tools

CREO

3D CAD modeling software

FEA tools

Job description

W3Global is seeking an experienced Senior Mechanical (Design) Engineer for aerospace/defense, onsite in Whippany, NJ. You will lead design, analysis, testing, and production release of complex mechanical systems and mechanisms, including gear drives, power transmission, braking, actuation, and related control systems.

The role requires 10+ years in regulated aerospace environments, strong GD&T/ASME Y14.5 skills, CREO CAD expertise, and hands-on qualification testing experience to support