Sr. Design Engineer - Electro-Mechanical Actuation

Regal Rexnord•Downers Grove, IL

5d•$83,500 - $130,000•Hybrid

About The Position

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.

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

Responsibilities

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