Senior Design Engineer

Job Description

Arrowhead Talent Solutions is helping a manufacturing company find a Design Engineer in Wadsworth, Ohio.

The role will focus on developing custom gearbox and transmission solutions for industries such as aggregate, marine, metals, mining, recycling, and material processing. The engineer will serve as the internal expert for gear system design and development, leading concept-to-production efforts and mentoring other engineers. On-site presence is required and occasional customer and supplier visits may be needed.

**Responsibilities**

* Lead development of transmissions, gearboxes, and gear subsystems (spur, helical, bevel, planetary) from concept through production release, including gear geometry, heat treatment requirements, shafts, bearings, housings, seals, and lubrication systems.
* Collaborate with application engineering teams and customers to understand duty cycles and convert them into detailed gearbox specifications.
* Perform and validate gear calculations, including load capacity, AGMA/ISO design calculations, contact pattern analysis, bending and pitting/scuffing safety factors, and bearing life calculations.
* Develop tolerance stack-ups, interference/clearance analyses, and fit/assembly procedures to ensure robust performance across manufacturing and service conditions.
* Define testing requirements and oversee gearbox test programs to validate durability, NVH performance, and thermal stability.
* Work closely with manufacturing, quality, and suppliers to ensure designs meet requirements, are manufacturable, and cost-effective.
* Resolve production or field issues using structured 8D problem-solving and implement robust engineering changes.
* Serve as the internal authority for gear design; develop best-practice standards, calculation templates, design guidelines, and training materials.
* Support development of dry and wet friction clutches, brakes, and related drivetrain components.

**Qualifications**

* BS in Mechanical Engineering (or related) with 7 years of gearbox/gear design experience, OR MS in Mechanical Engineering (or related) with 5 years of experience, OR Equivalent combination of education and experience.
* Proficiency in AGMA or ISO gear design methods, gear tooth strength/contact calculations, and bearing life calculations.
* Experience with tolerance stack-ups, fits, assembly techniques, and GD\&T.
* Proven experience developing and overseeing gearbox test plans and drivetrain validation.
* Strong CAD skills (CREO preferred; SolidWorks, Inventor, or similar acceptable) and familiarity with PDM/PLM systems.
* Experience with gear analysis software (KISSsoft preferred; ROMAX, MITCALC, or similar) and FEA tools (ANSYS preferred; Abaqus or similar).
* Experience with automatic, automated manual, dual-clutch, manual, or powershift transmissions across electrified, hybrid, or internal combustion powertrains.
* Background in tribology, lubrication system design, NVH mitigation, and thermal management.
* Experience with dry/wet friction clutches, brakes, and fluid couplings.
* Experience collaborating with embedded controls and hydraulic systems engineers for multi-speed gearbox control systems.
* Understanding of linear and torsional vibration in gear, bearing, and rotating shaft systems.
* Proven ability to establish design standards, training programs, and technical references.
* Training or certifications in gear design, failure analysis, gear analysis software, bearing selection, contact mechanics, FEA, NVH, tribology, product development/testing, and GD\&T (ASME Y14.5).
* Participation in relevant technical societies (AGMA, AIAG, ASME, SAE, STLE, etc.).