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Mechanical Engineer (Gears)
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OSI Engineering
Remote
$182,000 Salary, Full-Time
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Job Description
Mechanical Engineer (Gears) at OSI Engineering Mechanical Engineer (Gears) at OSI Engineering in Los Altos, California Posted in 1 day ago.
Type:
full-timeJob Description:
A globally leading consumer device company based in Sunnyvale, CA is seeking a highly skilled Gear Design Subject Matter Expert (SME) to join our 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 products.Key Responsibilities:
- Lead micro gear design efforts from concept through production, including gear tooth geometry definition, material selection, and tolerance analysis for miniaturized assemblies.
- 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 countermeasures.
- 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:
- M.S. or Ph.D. in Mechanical Engineering, Applied Mechanics, or closely related field
- 5+ years of hands-on gear design experience, with at least 3 years focused on miniature/microscale gear systems
- Expert-level knowledge of gear mesh theory, contact mechanics, and gear noise generation mechanisms
- Demonstrated experience reducing gear noise through profile optimization, micro-geometry modifications, and system-level tuning
- Proficiency with gear-specific software (KISSsoft, MASTA, Penn State GearLab tools, or equivalent) and general FEA (ANSYS, Abaqus)
- Deep familiarity with micro-manufacturing processes and their impact on achievable tolerances and surface quality
- Experience with gear metrology (CMM, gear checkers, surface profilometry) at fine pitch/module scales
Preferred Qualifications:
- Experience with polymer and composite gears for noise-sensitive applications
- 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.