Mechanical Engineer (Gear Design Subject Matter Expert)

Akkodis is seeking a – “Mechanical Engineer IV (Gear Design Subject Matter Expert)” for a Contract position with a client located in Sunnyvale, CA (Onsite).

Pay Range: $80 - $90/hour. (The rate/salary may be negotiable based on experience, education, geographic location, and other factors.)

Job Description

Gear Design Subject Matter Expert — Micro Gear System

Position Summary:

We are seeking a highly skilled Gear Design Subject Matter Expert (SME) to join Hardware Technologies team, focusing on the design, analysis, and optimization of micro-scale gear systems. The ideal candidate will bring deep expertise in precision gear engineering with a primary focus on size reduction and acoustic noise minimization. This role will drive innovation in compact mechanical drive systems for next-generation consumer hardware product

Key Responsibilities.

• Lead micro gear design efforts from concept through production, including gear tooth geometry definition, material selection, and tolerance analysis for miniaturized assembli
• Develop and optimize gear profiles (involute, cycloidal, and non-standard tooth forms) to minimize transmission error, contact stress, and audible noise in sub-millimeter to single-digit-millimeter scale geartrains.
• Perform detailed acoustic and vibration analysis of gear mesh interactions, identifying root causes of noise (mesh harmonics, ghost frequencies, hunting tooth effects) and implementing design countermeasure
• Drive gear system miniaturization by evaluating novel architectures (planetary, harmonic drive, strain wave, compound epicyclic) and emerging micro-manufacturing processes (LIGA, micro-EDM, micro-injection molding, photochemical etching.
• Define and validate gear specifications including module/DP, pressure angle, profile shift, tip relief, lead/profile crowning, and surface finish requirements tailored to micro-scale constraints. Collaborate with cross-functional teams including mechanical design, acoustics, materials science, manufacturing, and reliability engineering to deliver integrated solutions meeting aggressive size, noise, and lifetime targets.
• Develop and maintain predictive models (FEA, multi-body dynamics, semi-analytical contact models) for gear mesh stiffness variation, transmission error, and NVH performance.
• Establish design guidelines and best practices for micro gear systems, including DFM/DFA rules, inspection criteria, and qualification test protocols
• Evaluate and qualify new materials and coatings (engineering polymers, MIM metals, DLC coatings, ceramic composites) for noise reduction and wear performance at micro scale.

Required Qualifications: Education: M.S. or Ph.D. in Mechanical Engineering, Applied Mechanics, or closely related field.

Experience: 5 years of hands-on gear design experience, with at least 3 years focused on miniature/microscale gear systems.

• Gear Theory: Expert-level knowledge of gear mesh theory, contact mechanics, and gear noise generation mechanical
• Noise/NVH: Demonstrated experience reducing gear noise through profile optimization, micro-geometry modifications, and system-level tuning.
• Analysis Tools: Proficiency with gear-specific software (KISSsoft, MASTA, Penn State GearLab tools, or equivalent) and general FEA (ANSYS, Abaqus.
• Manufacturing: Deep familiarity with micro-manufacturing processes and their impact on achievable tolerances and surface quality.
• Metrology: Experience with gear metrology (CMM, gear checkers, surface profilometry) at fine pitch/module scales.

Preferred Qualification.

• Experience with polymer and composite gears for noise-sensitive application.
• Familiarity with acoustic measurement and analysis (sound power, order tracking, transfer path analysis.
• Knowledge of tribology and lubrication strategies for enclosed micro gearboxes.
• Experience with tolerance stack-up and statistical methods (Monte Carlo, Six Sigma) applied to micro assemblies.
• Background in consumer electronics, medical devices, or watchmaking (industries with strict size and noise constraints).Publications or patents in gear noise reduction or micro-mechanism design.
• Hands-on prototyping experience with additive manufacturing (SLA, etc.) for micro gear feasibility studies Key Performance Metrics.
• Size reduction: Achieve gear system envelope reductions of vs. baseline designs while maintaining torque and lifetime requirements.
• Noise targets: Meet or exceed product-level acoustic specifications (typically ≤25 dBA at 10 cm in quiet environments.
• Reliability: Gear systems pass accelerated life testing with zero wear-out failures within design

If you are interested in this role or have any questions, please feel free to contact me at 610-445-0024 or ajay.singh@akkodisgroup.com

Equal Opportunity Employer/Veterans/Disabled

Benefit offerings available for our associates include medical, dental, vision, life insurance, short-term disability, additional voluntary benefits, an EAP program, commuter benefits, and a 401K plan. Our benefit offerings provide employees the flexibility to choose the type of coverage that meets their individual needs. In addition, our associates may be eligible for paid leave, including Paid Sick Leave or any other paid leave required by Federal, State, or local law, as well as Holiday pay, where applicable. Disclaimer: These benefit offerings do not apply to client-recruited jobs and jobs that are direct hires to a client.

To read our Candidate Privacy Information Statement, which explains how we will use your information, please visit https://www.akkodis.com/en/privacy-policy.

The Company will consider qualified applicants with arrest and conviction records in accordance with federal, state, and local laws and/or security clearance requirements, including, as applicable:

• The California Fair Chance Act
• Los Angeles City Fair Chance Ordinance
• Los Angeles County Fair Chance Ordinance for Employers
• San Francisco Fair Chance Ordinance