Mechanical Design Engineer – Bearings, Sumps & Oil Systems
LevelUP HCS · Abu Dhabi Emirate, United Arab Emirates
Apply & track with Apply EdgeThis role is responsible for bearing chambers, sump structures, oil feed and scavenge systems, sealing interfaces, and associated thermal and structural design considerations, ensuring reliability, performance, maintainability, and certification compliance across military and commercial engine programs.
Key Responsibilities
Mechanical Design & DevelopmentLead the mechanical design of bearing compartments, sump housings, oil nozzles, scavenge features, and support structures for rotating shafts and engine modules.Develop and manage 3D CAD models and detailed engineering drawings for:Oil feed and scavenge systems (tubes, fittings, and manifolds)Bearing supports and retention systemsSump pressurization and ventilation systemsDynamic seals, flinger rings, and deflectorsEnsure designs meet functional, structural, and thermal requirements across engine operating conditions and duty cycles.Structural & Thermal IntegrationCollaborate with stress and thermal analysis teams to evaluate:Fatigue and static strength of sump and bearing support structuresOil coking, sludge formation, and heat rejection risksVibration-induced wear, oil leakage risks, and system dynamicsEnsure mechanical integrity under high-temperature, oil-laden, and rotating operating environments.Sealing & Lubrication SystemsDesign and integrate dynamic sealing technologies, including labyrinth, brush, and carbon face seals. Develop oil system routing strategies that account for pressure losses, thermal effects, and serviceability requirements. Ensure accessibility, maintainability, and durability while meeting certification and performance objectives.Manufacturing & Assembly SupportApply Design for Manufacturability (DFM) principles across forged, cast, and machined housings and plumbing assemblies.Define component tolerances, interfaces, and joining methods for complex mechanical assemblies.Support supplier qualification activities, tooling reviews, and producibility assessments. Participate in engine build, integration, and test readiness reviews. Documentation & CertificationPrepare and release technical documentation, including:Design reports and engineering drawingsTolerance stack-up analysesFailure mode assessments and risk mitigation plansMaterial selection and justification documentationSupport FAA/EASA certification activities and internal/external technical reviews.Contribute to Preliminary Design Reviews (PDR), Critical Design Reviews (CDR), and hardware readiness reviews. Cross-Functional CollaborationWork closely with:Lubrication systems and thermal management engineersEngine systems and module integration teamsTest engineers supporting rig and engine validationMaintenance and supportability teams supporting MRO readinessSupport bearing loading assessments, alignment studies, oil condition management, and validation activities. Innovation & Continuous ImprovementInvestigate and implement emerging technologies, including:Additively manufactured oil channels and heat exchangersSelf-pressurizing sump conceptsAdvanced oil routing mechanismsEnhanced sealing technologiesApply lessons learned to improve bearing life, reduce oil system complexity, minimize leakage, and enhance maintainability.
Requirements
Strong experience designing bearing systems, sump structures, and lubrication systems within aerospace or turbomachinery applications. Good understanding of tribology, oil flow dynamics, sealing technologies, and rotating machinery systems. Experience developing engineering designs through the full product lifecycle, from concept through testing, certification, and in-service support.Knowledge of aerospace certification requirements and quality standards.Strong GD&T capability and engineering drawing interpretation skills. Education & Experience:Bachelor’s Degree in Mechanical Engineering or Aerospace Engineering is required. Master’s Degree is preferred, particularly in rotating machinery, thermal systems, or tribology. 5-15 years of experience in the design and development of bearing, sump, or oil system components within aerospace or turbomachinery environments. Proven experience supporting components through concept development, testing, certification, and field support activities.Key Skills:Proficiency with 3D CAD tools such as CATIA, NX, or equivalent. Familiarity with FEA tools for structural and thermal analysis. Expertise in tribology, lubrication systems, sealing technologies, and oil flow behaviour. Knowledge of FAA/EASA regulatory requirements and aerospace quality standards.Strong understanding of bearing support systems, rotor dynamics, and vibration-related design considerations. Excellent problem-solving, technical communication, and cross-functional collaboration skills.
Preferred Experience
Experience with oil system test rigs and associated instrumentation, including flow, pressure, temperature, and debris monitoring systems. Familiarity with bearing degradation mechanisms, vibration analysis, and rotor dynamics. Knowledge of oil system certification requirements, leakage control, and venting regulations. Exposure to digital twin technologies and health monitoring systems for lubrication and rotating equipment. Relocation support to Abu Dhabi is available for exceptional international candidates.