Mechanical Engineer

Staff Engineer, Mechanical
Montville NJ area
Temp to Direct Hire 40 hours weekly, On-Site
Must be a US Citizen with the ability to hold a security clearance.
The Staff Engineer is responsible to complete and contribute in the design, development, testing, qualification, and production support of products in a cost effective and timely fashion to meet the customer’s needs and schedules. The engineer shall work within a multi-disciplined organization and enlist the help of other disciplines when necessary, such as other engineers, manufacturing, purchasing, and quality assurance.
Primary Responsibilities:

• Design Electromechanical Actuators from a blank sheet of paper to meet customer requirements.
  • Design of spur, bevel, worm, and planetary gears
  • Design and analysis of kinematic mechanisms i.e., Slider Crank, Scotch Yoke, 4-Bar
  • Sizing and selection of Ball Screws capable of meeting system performance requirements
  • Sizing and selection of Bearings (Radial, Thrust, Angular contact) to meet loads and life necessary to meet system performance
  • Familiar with Brushless DC motor design
• Create and modify drawings with appropriate GD&T, documentation of change and efficacy. Verify Bill of Material. Ensure accuracy of drawings.
• Design cost effective easily manufacturable hardware taking into account:
  • tolerance stack-ups
  • ease of assembly
  • meet customer installation requirements
  • materials of construction
  • methods of manufacture
  • mechanical environment (Thermal and Vibe) and Application Loading
  • preliminary analytical results (Hand calculations and FEA)
  • mistake proofing
• Disposition non-conforming hardware and correct production/vendor issues.
• Perform failure investigations of designs.
• Create/Review and Approve processes for assembly, test, and related activities to the development and qualification testing of a design.
• Interface with internal and external customers to determine product changes needed for applications as a representative of the company.
• Write technical documents for internal and external customers.
• Participate in design reviews (internal and external)
• Support new business pursuits that address program technical requirements and associated schedule and costs.
• Mentor and Guide Junior team members

Qualifications/Knowledge/Skills Required:

• Bachelor’s Degree in Mechanical Engineering
• 8+ years’ experience and technical knowledge in Mechanical Engineering design of hardware preferably in aerospace or defense industry.
• Experience designing and testing designs to Mil-Std-810 Environments or similar (Humidity, Salt Fog, Vibration and Shock etc.)
• Excellent verbal and written communication skills.
• Experience solving technical problems using a methodical scientific approach.
• Experience in 3D modeling of mechanical components and assemblies preferably CREO
• Experience with Electromechanical Actuation Servo Systems
• Experience with Brushless DC motor design and or operation
• Experience with Finite Element Analysis for Structural, Thermal and Dynamic Analysis
• Possess organizational and task management skills to work concurrent issues in parallel.
• Leadership skills to interface with various other teams and disciplines at the company.
• Knowledge of manufacturing processes such as additive manufacturing, casting, milling, turning, grinding, drilling, etc.
• Must be a US Citizen, ability to obtain and maintain a security clearance.