Senior Gear Design Engineer

Responsibilities

• Own gear design end-to-end: system-level sizing, macro and micro geometry definition, rating and life analysis, prototyping, validation, and ramp to mass production.
• Perform gear sizing, contact/bending stress analysis, and micro-geometry optimization (profile and lead modifications) in KISSsoft to meet efficiency, durability, backlash, and NVH targets.
• Design gears, shafts, and transmission assemblies in 3D CAD (CATIA) that satisfy extreme packaging, load, and durability requirements of a high-DOF robotic hand.
• Define gear manufacturing strategy - cutting, grinding, powder metal, MIM, or plastics - and drive DFM with suppliers from first articles through high-volume production.
• Generate accurate 2D drawings with gear data tables and GD&T per ASME Y14.5, and define inspection and metrology plans for incoming quality.
• Build and run test rigs to characterize efficiency, backlash, wear, and fatigue life; correlate test data back to analytical models.
• Collaborate closely with actuator, structures, EE, and manufacturing teams - proactively identifying risks, driving decisions, and unblocking the program without waiting to be asked.

Requirements

• 7+ years of experience designing gears and geared transmissions.
• Bachelor's or Master's Degree in Mechanical Engineering, Robotics, Mechatronics, or similar field.
• Demonstrated ownership of complete gear designs from initial sizing through mass manufacturing.
• Proficiency in KISSsoft (or equivalent) for gear rating, contact analysis, and micro-geometry optimization.
• Proficiency in CATIA (or equivalent high-end 3D CAD) for complex geometry and large assemblies.
• Working knowledge of AGMA/ISO gear rating standards, gear metrology, and tolerancing.
• Experience with gear manufacturing processes (hobbing, shaping, skiving, grinding, powder metal, MIM, or injection molding) and supplier development.
• A strong team player with a high sense of agency - you take ownership of outcomes, communicate openly, and elevate the people around you.

Bonus Qualifications

• Experience with small-module, high-ratio, or high-power-density gearing (planetary, cycloidal, or strain wave).
• Experience in robotics, surgical devices, aerospace actuation, or automotive e-drive transmissions.
• Familiarity with lubrication selection, grease DOE, and tribology for compact gearboxes.
• Experience with fatigue modeling, bearing life characterization, and accelerated life testing.
• Experience taking a product through NPI builds (EVT/DVT/PVT) and FATP at volume.

Pay and benefits

The US base salary range for this full-time position is $160,000 to $250,000 per year.

The pay offered for this position may vary based on several individual factors, including job-related knowledge, skills, and experience. The total compensation package may also include additional components/benefits depending on the specific role. This information will be shared if an employment offer is extended.