Static Structures Designer - Gearbox & Rotor Drive System

NORTHSTAR AEROSPACE•Bedford Park, IL

4d•$86,000 - $130,000•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 Static Structures Designer will own the design of Accessory/Power Gearboxes and Rotor Drive Systems (RDS) from concept through certification and entry into service within the full NPI lifecycle. This position is responsible for static structural hardware, driving integration for maximum performance and productivity, and supporting legacy products to ensure reliable hardware deliveries.

Requirements

Bachelor’s degree in a Mechanical Engineering and/or Mechanical Design discipline from an accredited university or college

Nice To Haves

Bachelor’s degree in Mechanical or Aeronautical Engineering from an accredited university or college
Experience in static component design such as housings, covers, adaptors, mounts, and brackets
Background in complex mechanical systems, ideally in gearbox systems and/or components
Technical knowledge of power gearbox manufacturing processes
Understanding of gearbox technical requirements, design processes and solutions, and technologies/materials for aeronautical static structures, including light alloys, alloys for mounting systems, and surface treatments/coatings for corrosion protection
Experience with CAD tools (for example Unigraphics NX) and CAE tools (for example Nastran, Ansys).
Strong analytical and problem‑solving skills, with a clear, structured, and diligent approach
Strong oral and written communication; able to work cross‑functionally and present technical content clearly
High motivation and passion for mechanical design, curiosity, and a continuous‑improvement mindset
Prior experience in mechanical transmissions, developed on mechanical transmission systems or components and/or helicopter rotor drive systems.
Experience in a multicultural, international environment, with demonstrated ability to collaborate across geographies and time zones
Creativity and self‑confidence, with the ability to propose innovative solutions and challenge the status quo when appropriate
Strong teaming and influencing skills, with a collaborative mindset and respect for diverse perspectives

Responsibilities

Use technical expertise to solve problems, execute objectives with positive impact short‑term and mid‑term business goals.
Own static structure components design across multiple programs (new introduction and in-service).
Contribute to the definition of static structures from concept to detailed design, prototype manufacturing/procurement, testing, certification, and entry into service.
Create and update 3D models and 2D drawings using standard CAD tools while ensuring adherence to GE and Avio Aero 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 design, meet performance, cost, weight and reliability.
Develop and strengthen technical expertise for static components in aeronautical gearboxes (housings, brackets, adapters, mounts, covers, etc.)
Define subsystems and components, identify alternatives, define and agree on CTQs (Critical to Quality), run trade studies, and down‑select the optimal solution to meet performance, cost, weight, and manufacturability targets.
Collaborate with customers, System Engineers, and senior experts on design trade studies, risk assessments, and product definition.
Support Request for Information (RFI) and Request for Proposal (RFP) responses with open collaboration to senior experts and module designers.
Actively contribute to design reviews, substantiating and endorsing proposed design solutions with sound engineering rationale and analysis.
Extend support across product life phases (Advanced Technology programs and Services) as needed.
Stay current on state‑of‑the‑art technologies and methods in your field; identify training needs, share best practices, and help elevate technical capability across the design organization.
Identify and recommend technical training and improvements, contributing to the development of technical excellence within the design community.
Address quality notes and field issues for legacy products, ensuring timely, high-quality dispositions and uninterrupted hardware deliveries.
Coordinate activities with the US‑based team and integrate work across the extended international team, ensuring alignment on part‑family scope and technical solutions.
Travel up to 50% (domestic and international)