Sr. Design Engineer - Electro-Mechanical Actuation

API Delevan, Inc.; Downers Grove (IL); Hybrid; USD 84,000 - 130,000; Full time

Benefits offered by this job

Medical, Dental, Vision

HSAs and FSA

Paid Time Off

401k with matching

AD&D Insurance

Tuition Assistance

Job summary

Regal Rexnord is seeking a technical lead for Electro-Mechanical Actuation aerospace products. You will own the actuator design lifecycle, lead architecture decisions, and drive cross-functional collaboration to deliver flight-critical actuation systems.

The role requires 7+ years in EMA engineering, strong CAD skills, and hands-on experience with lean manufacturing and root-cause analysis. Hybrid workModel with on-site days and remote flexibility, plus a broad benefits package.

Qualifications

• Bachelor's degree in Mechanical or Aerospace Engineering or related field.
• 7+ years of EMA or related engineering experience.
• Advanced knowledge of electro-mechanical actuators and their operation.
• Proficiency in 3D CAD and GD&T.
• Experience in metal manufacturing and PPAP/APQP tools.
• Experience with lean manufacturing and root-cause analysis.

Responsibilities

• Lead system architecture, sizing, and design of electro-mechanical actuators.
• Own actuator design lifecycle from concept to production and lead design reviews.
• Define test plans and correlate analysis with test data.
• Collaborate with suppliers, component teams, and manufacturing to ensure integrability and producibility.
• Drive program milestones while balancing performance, cost, weight, and schedule.
• Identify continuous improvement opportunities within facilities and supplier locations.

Skills

Actuation design

System architecture

Project management

Root cause analysis

3D CAD (SolidWorks/Inventor/CREO/CATIA

Lean / Continuous improvement

Education

Bachelor's degree in Mechanical or Aerospace Engineering

Tools

SolidWorks

Inventor

CREO

CATIA

Job description

Work Model

Work Model: Work Model: You’ll work in a hybrid model, onsite at your designated Regal Rexnord location at least 3 days per week (Monday–Thursday), with flexibility to work remotely up to 2 days, including Friday.

Position Summary

This position will serve as technical lead and owner for Electro-Mechanical Actuation aerospace products. The engineer is responsible for the design, development, integration and validation of the actuator designs, including motor, gears, drive mechanisms, sensors and structural housings. The position works closely with customers and cross-functional engineering teams to deliver high-performance, flight-critical actuation systems for next-generation aircraft platforms.

Key Accountabilities

Technical Leadership and System Design

Lead system architecture, sizing, and design of electro-mechanical actuators (motor, gearing, ball screw/roller screw, position sensing). Perform analysis and design studies (torque-speed, position accuracy, life, safety and reliability). Define and manage requirements flow-down to the actuator component level.

Product Development

Own actuator design through full lifecycle (concept → qualification → production). Lead design reviews (PDR, CDR) and ensure technical readiness. Develop and maintain engineering models, drawings, and specifications.

Testing and Validation

Define and support component and system-level test plans. Correlate analysis with test data and drive design improvements. Lead root cause investigations for test or field failures.

Cross-Functional Engineering Collaboration

Partner with component engineers, suppliers and manufacturing engineers to ensure proper integration. Provide technical oversight to suppliers. Drive DFM/DFA considerations and ensure producibility.

Program Execution

Lead technical execution against program milestones and deliverables of numerous new product introductions. Balance performance, cost, weight, and manufacturability in design decisions. Support customer interactions with technical expertise. Assess and adapt to the impact of material availability, long-lead components, and supplier delivery schedules on engineering development, build plans, and program milestones.

Continuous Improvement

Assist in Identifying & driving continuous improvement opportunities within the facilities and at our supplier's locations. Contribute to the breakthrough product development process Maintain and improve existing products Create and maintain policies, procedures, engineering standards, programs, and work instructions.

Job Requirements

• Requires a Bachelor's degree in Mechanical Engineering or Aerospace Engineering or related discipline
• 7 + years of EMA or related engineering work experience
• Advanced knowledge in the application, design and theory of operations for electro-mechanical actuators
• Working knowledge of 3D Solid Modeling software such as SolidWorks, Inventor, CREO, and/or CATIA
• Advanced knowledge of engineering part drawings and Geometric Dimensioning and Tolerancing
• Background in metal manufacturing environment including metal cutting and grinding
• General working knowledge of the Production Part Approval Process (PPAP) and Advanced Product Quality Planning (APQP) tools
• Knowledge of Stage-Gate development processes
• Experience working in a lean manufacturing or continuous improvement environment is required
• Experience in root cause analysis and formal problem-solving techniques
• Demonstrated proficiency in time and project management
• Strong customer service orientation/ High level of interpersonal skills
• Capable of occasional travel to customers and plants

Expected Base Salary Range

Expected Base Salary Range: [$83,500 – $130,000] The salary range provided is intended to display the value of the company's base pay compensation for this position. Salary is dependent on a multitude of factors, including but not limited to the physical worksite location, the geographic market of that location, candidate's skill set, level of experience, education and internal peer compensation comparisons among other potential factors.

Benefits

• Medical, Dental, Vision and Prescription Drug Coverage
• Spending accounts (HSA, Health Care FSA and Dependent Care FSA)
• Paid Time Off and Holidays
• 401k Retirement Plan with Matching Employer Contributions
• Life and Accidental Death & Dismemberment (AD&D) Insurance
• Paid Leaves
• Tuition Assistance

About Regal Rexnord

Regal Rexnord is a publicly held global industrial manufacturer with 30,000 associates around the world who help create a better tomorrow by providing sustainable solutions that power, transmit and control motion. The Company’s electric motors and air moving subsystems provide the power to create motion. A portfolio of highly engineered power transmission components and subsystems efficiently transmits motion to power industrial applications. The Company’s automation offering, comprised of controls, actuators, drives, and precision motors, controls motion in applications ranging from factory automation to precision control in surgical tools. The Company’s end markets benefit from meaningful secular demand tailwinds, and include factory automation, food & beverage, aerospace, medical, data center, warehouse, alternative energy, residential and commercial buildings, general industrial, construction, metals and mining, and agriculture. Regal Rexnord is comprised of three operating segments: Industrial Powertrain Solutions, Power Efficiency Solutions, and Automation & Motion Control. Regal Rexnord has offices and manufacturing, sales and service facilities worldwide. For more information, including a copy of our Sustainability Report, visit RegalRexnord.com.

Equal Employment Opportunity Statement

Regal Rexnord is an Equal Opportunity and Affimate action. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex/gender, sexual orientation, gender identity, pregnancy, age, ancestry, national origin, genetic information, marital status, citizenship status (unless required by the applicable law or government contract), disability or protected veteran status or any other status or characteristic protected by law. Regal Rexnord is committed to a diverse and inclusive workforce. We are committed to building a team that represents diverse and inclusive backgrounds, perspectives, and skills. If you’d like to view a copy of the company’s affirmative action plan for protected veterans/individuals with disabilities or policy statement, please email [e-mail]. If you have a disability and you believe you need a reasonable accommodation in order to search for a job opening or to submit an online application, please e-mail [e-mail]. Notification to Agencies: Please note that Regal Rexnord Corporation and its affiliates and subsidiaries ("Regal Rexnord") do not accept unsolicited resumes or calls from third-party recruiters or employment agencies. In the absence of a signed Master Service Agreement or similar contract and approval from HR to submit resumes for a specific requisition, Regal Rexnord will not consider or approve payment to any third-parties for hires made.

Our Values

Our values frame our culture - a shared understanding of how we think and act relative to our key stakeholders. We center our behaviors, actions and decisions around the following values: Integrity Responsibility Diversity, Engagement & Inclusion Customer Success Innovation with Purpose Continuous Improvement Performance Passion to Win ….with a Sense of Urgency