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Gear Design information

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$22K

$85.7K

$154K

How much do gear design jobs pay per year?

As of Jul 28, 2026, the average yearly pay for gear design in the United States is $85,667.00, according to ZipRecruiter salary data. Most workers in this role earn between $55,500.00 and $108,500.00 per year, depending on experience, location, and employer.

What are the key skills and qualifications needed to thrive in the Gear Design position, and why are they important?

To thrive in Gear Design, you need a strong background in mechanical engineering, sound knowledge of gear theory, materials science, and CAD proficiency, often supported by a relevant engineering degree. Familiarity with design software like SolidWorks or CATIA, and analysis tools such as ANSYS or KISSsoft, as well as industry certifications, are commonly expected. Excellent problem-solving abilities, attention to detail, and effective teamwork and communication skills are essential soft skills in this field. These qualifications are critical to ensure the development of precise, reliable, and cost-effective gear systems that meet industry standards and performance requirements.

What is a Gear Design job?

A Gear Design job involves creating and optimizing gears for mechanical systems, ensuring they meet performance, durability, and efficiency requirements. Engineers in this role use CAD software and engineering principles to design gears for applications in automotive, aerospace, industrial machinery, and more. They analyze factors like load capacity, material selection, and manufacturing processes to ensure reliable gear operation. Collaboration with manufacturing teams and testing prototypes are also key aspects of the job.

What are some of the typical challenges faced in a Gear Design role, and how are they addressed?

Gear Design professionals often deal with challenges such as optimizing gear performance while balancing constraints like weight, cost, and manufacturability. They must account for factors like material selection, load requirements, and noise reduction, all while ensuring the gears can be produced efficiently at scale. Overcoming these challenges usually involves working closely with cross-functional teams—including manufacturing, quality assurance, and R&D—to validate designs and test prototypes. Staying updated with new materials and design methodologies also helps address evolving industry needs. Successful gear designers are adaptable and proactive in researching solutions to deliver innovative and reliable components.

More about Gear Design jobs
What states have the most Gear Design jobs? States with the most job openings for Gear Design jobs include:
What job categories do people searching Gear Design jobs look for? The top searched job categories for Gear Design jobs are:
Gear Design jobs near you
Infographic showing various Gear Design job openings in the United States as of July 2026, with employment types broken down into 50% Full Time, and 50% Part Time. Highlights an 100% In-person job distribution, with an average salary of $85,667 per year, or $41.2 per hour.

Senior Design Engineer

Arrowhead Talent Solutions

Wadsworth, OH • On-site

Full-time

Posted 9 days ago

Job description

Arrowhead Talent Solutions is helping a manufacturing company find a Design Engineer in Wadsworth, Ohio.
The role will focus on developing custom gearbox and transmission solutions for industries such as aggregate, marine, metals, mining, recycling, and material processing. The engineer will serve as the internal expert for gear system design and development, leading concept‑to‑production efforts and mentoring other engineers. On‑site presence is required and occasional customer and supplier visits may be needed.
Responsibilities
  • Lead development of transmissions, gearboxes, and gear subsystems (spur, helical, bevel, planetary) from concept through production release, including gear geometry, heat treatment requirements, shafts, bearings, housings, seals, and lubrication systems.
  • Collaborate with application engineering teams and customers to understand duty cycles and convert them into detailed gearbox specifications.
  • Perform and validate gear calculations, including load capacity, AGMA/ISO design calculations, contact pattern analysis, bending and pitting/scuffing safety factors, and bearing life calculations.
  • Develop tolerance stack‑ups, interference/clearance analyses, and fit/assembly procedures to ensure robust performance across manufacturing and service conditions.
  • Define testing requirements and oversee gearbox test programs to validate durability, NVH performance, and thermal stability.
  • Work closely with manufacturing, quality, and suppliers to ensure designs meet requirements, are manufacturable, and cost‑effective.
  • Resolve production or field issues using structured 8D problem‑solving and implement robust engineering changes.
  • Serve as the internal authority for gear design; develop best‑practice standards, calculation templates, design guidelines, and training materials.
  • Support development of dry and wet friction clutches, brakes, and related drivetrain components.

Qualifications
  • BS in Mechanical Engineering (or related) with 7+ years of gearbox/gear design experience, OR MS in Mechanical Engineering (or related) with 5+ years of experience, OR Equivalent combination of education and experience.
  • Proficiency in AGMA or ISO gear design methods, gear tooth strength/contact calculations, and bearing life calculations.
  • Experience with tolerance stack‑ups, fits, assembly techniques, and GD&T.
  • Proven experience developing and overseeing gearbox test plans and drivetrain validation.
  • Strong CAD skills (CREO preferred; SolidWorks, Inventor, or similar acceptable) and familiarity with PDM/PLM systems.
  • Experience with gear analysis software (KISSsoft preferred; ROMAX, MITCALC, or similar) and FEA tools (ANSYS preferred; Abaqus or similar).
  • Experience with automatic, automated manual, dual‑clutch, manual, or powershift transmissions across electrified, hybrid, or internal combustion powertrains.
  • Background in tribology, lubrication system design, NVH mitigation, and thermal management.
  • Experience with dry/wet friction clutches, brakes, and fluid couplings.
  • Experience collaborating with embedded controls and hydraulic systems engineers for multi‑speed gearbox control systems.
  • Understanding of linear and torsional vibration in gear, bearing, and rotating shaft systems.
  • Proven ability to establish design standards, training programs, and technical references.
  • Training or certifications in gear design, failure analysis, gear analysis software, bearing selection, contact mechanics, FEA, NVH, tribology, product development/testing, and GD&T (ASME Y14.5).
  • Participation in relevant technical societies (AGMA, AIAG, ASME, SAE, STLE, etc.).

Apply