Lead Static Structures Designer - Gearbox & Rotor Drive System

NORTHSTAR AEROSPACE•Bedford Park, IL

4d•$112,000 - $186,000•Onsite

About The Position

Northstar Aerospace, now part of Avio Aero - a GE Aerospace Company, is a leading independent manufacturer of components and assemblies to the global Aerospace industry. Our principal products include gears and transmissions, accessory gearbox assemblies, rotorcraft drive systems, and other machined and fabricated parts for helicopters and fixed-wing aircraft. We also provide maintenance and repair and overhaul (MRO) on these platforms. In this context we are reinforcing the focus to excellence in aeronautical Mechanical Transmissions (i.e. accessory drive-train, power gearboxes and rotor drive systems) with an expansion of the Design Engineering team in US offering distinctive solutions to our customers. The Lead Static Structures Designer will be responsible for the full lifecycle of the static structures of mechanical transmission systems across the full New Product Introduction (NPI) lifecycle, from concept and preliminary design to certification and entry into service. They will also deal with already in-service products to support new make parts or overhaul. The current portfolio includes several programs involving modules and parts for accessory and power gearboxes and helicopter Rotor Drive Systems (RDS), spanning both introduction-phase and in-service platforms.

Requirements

Bachelor’s degree from an accredited university or college
Minimum of 3 years of experience with mechanical systems’ static structures (ideally gearbox technical requirements, design process and solutions, technologies, and materials for typical light alloys structure applications)

Nice To Haves

Master’s degree in Mechanical or Aeronautical Engineering from an accredited university or college
Knowledge of power gearbox manufacturing processes, including understanding of gearbox technical requirements, design processes and solutions, and technologies/materials for aeronautical static structures (e.g. light alloys, mounting system alloys, coatings for corrosion and protection)
Experience with CAD and CAE tools, such as Unigraphics NX (or equivalent) and Nastran / Ansys (or equivalent)
Knowledge of structure design and analysis tools and methods
Clear, structured thinking and a diligent, systematic approach to problem-solving
Curiosity and passion for mechanical design
Significant experience in mechanical transmission design, gained on mechanical transmission systems/components and/or helicopter Rotor Drive Systems
International experience in the aeronautical field (study, work assignment, or project experience abroad)
Experience in functional coordination or technical leadership of small teams
Experience with New Product Introduction (NPI) processes in aerospace or similar high-technology industries

Responsibilities

Lead the design and validation of static components (e.g. housings, brackets, adapters, mounts) with a strong focus on casting-derived parts for both power and accessory applications.
Own the static structures design definition across the NPI process: concept design, detailed definition, prototype manufacturing/procurement, testing and certification.
Create and update 3D models and 2D drawings using standard CAD tools while ensuring adherence to GE design standards, specifications, and regulatory requirements.
Perform tolerance stack-ups, geometric dimensioning and tolerancing (GD&T), and design for manufacturability (DFM) to ensure robust, producible designs.
Support both new programs and legacy in‑service products, including quality note dispositions to ensure continuity of hardware deliveries.
Guide Finite Element (FE) simulations to characterize component behavior and guide product definition in line with integrity, life, cost, weight and performance requirements.
Contribute on strengthen the team’s technical capability in these areas.
Use your experience and expertise to solve complex technical problems, define and execute objectives for yourself and the broader part-family team, and contribute to both short‑term program milestones and long‑term business goals.
Design sub-systems and components, identify design alternatives, define and agree CTQs (Critical to Quality), perform scoring and trade-offs, and down-select the optimal solution to meet performance/cost/weight targets.
Support System Engineers and customer discussions on static structures topics (trade studies, risk assessments, etc.)
Contribute to Requests for Information (RFI) and Requests for Proposal (RFP), defining product architecture and technologies, and leading technical trade studies.
Capture and interpret system requirements and contribute to the flow-down to static component design, including certification strategy and design specification release.
Extend contributions across the product lifecycle, including advanced technology development and service/support phases when needed.
Apply knowledge of gearbox technical requirements, design processes, technologies, and materials for structural applications.
Provide technical leadership in design reviews, substantiating and endorsing proposed design solutions.
Support the Sub-Section Manager in coordinating internal and external design activities, defining scope of work and technical specifications, and assessing the team’s capabilities.
Provide functional coordination and technical leadership to peers working on the same part-family
Stay current on the state of the art in your discipline, apply best practices, and proactively propose improvements to senior experts and the wider community.
Work closely with a global team in Italy and the US, coordinating part family scope and ensuring alignment across sites.
Travel up to 50% (domestic and international)