Senior Mechanical 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

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.