Lead Rotating Parts Engineer - Gearbox & Rotor Drive System

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 Rotating Parts Engineer will be responsible for the full lifecycle of rotating hardware and mechanical transmission components and subsystems, from concept design through certification and entry into service, within the New Product Introduction (NPI) process. 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.

Roles and Responsibilities

• Use experience and expertise to solve complex technical problems, lead design activities across part families, and contribute to both short-term program goals and long-term company objectives.
• Own the design definition and the technical integrity of the assigned mechanical components (focus on shafts, gearshafts, couplings and in general rotating components) within the NPI process from concept design to product detailed definition, protypes 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.
• Apply knowledge of gearbox technical requirements, design processes, technologies, and materials for gear shaft and bearing applications.
• Define subsystem and component solutions, identify alternatives, and drive trade-off studies.
• Discuss technical solutions with customers, supporting System Engineers in product definition (e.g. rotating components trade studies, bearing selections, risk assessments, etc.)
• Contribute to the preparation of Requests for Information (RFI) and Requests for Proposal (RFP) for customers.
• Define product architecture and components with applied technologies.
• Agree on and manage CTQs (Critical to Quality) and down-select optimal design solutions to achieve performance, cost, weight, and reliability targets.
• Capture and flow-down system-level requirements to rotating components, including certification strategy and design specifications.
• Support the Sub-Section Manager in coordinating internal and external design activities, such as defining system/product scope of work, preparing technical specifications, and assessing capabilities.
• Provide functional coordination and technical leadership to peers working on the same part-family.
• Extend contributions across the product lifecycle, including advanced technology development and service/support phases when needed.
• Provide technical leadership in design reviews, substantiating and endorsing proposed design solutions.
• Work closely with an extended team, based in both Italy and the United States, ensuring aligned and integrated execution of work-scopes.
• Travel up to 50% (domestic and international)

Required Qualifications

• Bachelor’s degree from an accredited university or college
• Minimum of 3 years of experience with mechanical systems’ rotating parts (ideally gearbox technical requirements, design process and solutions, technologies, and materials for typical gears, gear shafts, bearings, and seals application

Preferred Qualifications

• Master’s degree in Mechanical or Aeronautical Engineering from an accredited university or college
• Experience with CAD tools (e.g. Unigraphics NX) and CAE tools (e.g. Nastran, Ansys)
• Knowledge of gear design and analysis tools
• Significant experience in mechanical transmission design, developed on transmission systems or components and/or helicopter rotor drive systems
• Direct experience with New Product Introduction (NPI) processes
• Clear, structured thinking and a diligent, detail-oriented approach
• Experience in functional coordination or technical leadership of small teams
• Experience with New Product Introduction (NPI) processes in aerospace or similar high-technology industries
• Strong interpersonal and communication skills, including the ability to work effectively in a multicultural and international environment
• Curiosity and passion for mechanical design

The specific pay offered may be influenced by a variety of factors, including the candidate’s experience, education, and skill set. This position is also eligible for an annual discretionary bonus based on a percentage of your base salary/commission based on the plan. 

At Northstar, we understand the importance of Total Rewards and offer varied benefit offerings based upon location.

• Medical, Dental and Vision Insurance
• Short Term and Long-Term Disability
• Life and AD&D Insurance
• Employee Assistant Program
• Employee Service Awards (service and recognition)
• Performance Bonus

This role requires access to U.S. export-controlled information. Therefore, employment will be contingent upon the ability to prove that you meet the status of a U.S. Person as one of the following: U.S. lawful permanent resident, U.S. Citizen, have been granted asylee or refugee status (i.e., a protected individual under the Immigration and Naturalization Act, 8 U.S.C. 1324b(a)(3)).

Additional Information

GE Aerospace offers a great work environment, professional development, challenging careers, and competitive compensation. GE Aerospace is an Equal Opportunity Employer. Employment decisions are made without regard to race, color, religion, national or ethnic origin, sex, sexual orientation, gender identity or expression, age, disability, protected veteran status or other characteristics protected by law.

GE Aerospace will only employ those who are legally authorized to work in the United States for this opening. Any offer of employment is conditioned upon the successful completion of a drug screen (as applicable).

Relocation Assistance Provided: No

Salary : $112,000 - $186,000