Bearings, Sumps, Oil Systems Mechanical Design Engineer

ABOUT THE ROLE The Senior Mechanical Design Engineer Bearings, Sumps & Oil Systems is responsible for the mechanical design, integration, and lifecycle development of rotating support and lubrication systems within turbofan propulsion architectures. This includes bearing chambers, sump structures, oil feed/scavenge lines, sealing interfaces, and associated thermal and structural design considerations. The role ensures mechanical robustness, system reliability, and certification compliance for both military and commercial engine applications. It requires strong cross-functional collaboration with systems, thermal, structural, and manufacturing teams. RESPONSIBILITIES Mechanical Design & Development • Lead mechanical design of bearing compartments, sump housings, oil nozzles, scavenge features, and support structures for rotating shafts and modules. • Develop and manage 3D CAD models and 2D detailed drawings of: • Oil feed and scavenge systems (tubes, fittings, manifolds) • Bearing supports and retention systems • Sump pressurization and ventilation elements • Dynamic seals, flinger rings, and deflectors • Ensure designs meet functional, structural, and thermal requirements across engine duty cycles. Structural & Thermal Integration • Collaborate with stress and thermal analysts to evaluate: • Fatigue and static strength of sump and bearing support structures • Oil coking, sludge, and heat rejection risks in bearing cavities • Vibration-induced wear, oil leakage risks, and system dynamics • Ensure mechanical integrity under high-temperature, oil-laden, and rotating conditions. Sealing & Lubrication Systems • Design and integrate dynamic sealing systems (labyrinth, brush, carbon face seals) between sump chambers and core flow paths. • Support oil system routing strategies that account for pressure drops, thermal gradients, and ease of maintenance. • Ensure component accessibility and maintainability while meeting certification and durability goals. Manufacturing & Assembly Support • Implement Design for Manufacturability (DFM) across forged, cast, and machined housings and plumbing assemblies. • Define tolerances, interfaces, and joining techniques for complex assemblies. • Support supplier qualification, tooling reviews, and producibility assessments. • Participate in engine build, test preparation, and integration reviews. Documentation & Certification • Prepare and release comprehensive technical documentation: • Design reports, stack-ups, and detailed drawings • Failure mode assessments, risk mitigation plans, and material justifications • FAA/EASA certification support documentation and internal/external technical reviews • Support PDR, CDR, and hardware readiness reviews with technical data packages. Cross-Functional Collaboration • Work closely with: • Lubrication systems and thermal management engineers for flow analysis and oil condition management • Engine systems and module integration teams for bearing loading, alignment, and interface design • Test engineers for sensor placement, rig setup, and oil system validation • Maintenance and supportability teams for MRO readiness and in-service performance insights Innovation & Continuous Improvement • Explore new technologies such as: • Additively manufactured oil channels and heat exchangers • Self-pressurizing sump designs or active oil routing mechanisms • Sealing systems that reduce oil leakage and environmental impact • Apply lessons learned to reduce oil system complexity, improve bearing life, and enhance maintainability. BASIC QUALIFICATIONS Education: • Bachelor s degree in Mechanical or Aerospace Engineering required • Master s degree preferred, particularly with a focus in rotating machinery, thermal systems, or tribology Experience: • 7 10 years of experience in the design and development of bearing, sump, or oil system components in aerospace or turbomachinery environments • Full lifecycle experience from concept through test, certification, and field support Technical Skills: • Proficiency in 3D CAD systems (CATIA, NX, or equivalent) • Familiarity with FEA tools for structural and thermal evaluation • Understanding of tribology, oil flow dynamics, and sealing technology • Knowledge of FAA/EASA regulatory standards and aerospace quality requirements • Strong GD&T knowledge and technical drawing preparation PREFERRED QUALIFICATIONS • Experience with oil system test rigs and instrumentation (e.g., oil flow, pressure, temperature, debris monitoring) • Familiarity with bearing degradation modes, vibration analysis, and rotor dynamics • Knowledge of oil system certification standards and environmental compliance (e.g., oil leakage control, venting regulations) • Exposure to digital twin and health monitoring tools for lubrication systems