Gear Design SME

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 Miniature/microscale gear requirement reduced from 3+ years to general precision gear design experience Considering candidates with strong gear NVH/noise reduction experience, even if they haven't worked extensively on micro-geometry optimization Experience in medical device industry and robotics would be relevant. 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.) for micro gear feasibility studies 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 #J-18808-Ljbffr OSI Engineering