Job Title: Mechanical Design Engineer – Bearings, Sumps & Oil Systems

Location: Abu Dhabi, United Arab Emirates (Relocation Opportunity)

Department: Product Engineering

Grade: Lead / Senior / Principal

Reporting to: Product Engineering Leadership Team

Job Purpose:

A leading aerospace and propulsion technology company based in Abu Dhabi is seeking a Mechanical Design Engineer – Bearings, Sumps & Oil Systems to lead the design, integration, and lifecycle development of rotating support and lubrication systems within advanced gas turbine propulsion architectures. This 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 & Development

Lead 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 systems
Sump pressurization and ventilation systems
Dynamic seals, flinger rings, and deflectors
Ensure designs meet functional, structural, and thermal requirements across engine operating conditions and duty cycles.

Structural & Thermal Integration

Collaborate with stress and thermal analysis teams to evaluate:
Fatigue and static strength of sump and bearing support structures
Oil coking, sludge formation, and heat rejection risks
Vibration-induced wear, oil leakage risks, and system dynamics
Ensure mechanical integrity under high-temperature, oil-laden, and rotating operating environments.

Sealing & Lubrication Systems

Design 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 Support

Apply 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 & Certification

Prepare and release technical documentation, including:
Design reports and engineering drawings
Tolerance stack-up analyses
Failure mode assessments and risk mitigation plans
Material selection and justification documentation
Support 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 Collaboration

Work closely with:
Lubrication systems and thermal management engineers
Engine systems and module integration teams
Test engineers supporting rig and engine validation
Maintenance and supportability teams supporting MRO readiness
Support bearing loading assessments, alignment studies, oil condition management, and validation activities.

Innovation & Continuous Improvement

Investigate and implement emerging technologies, including:
Additively manufactured oil channels and heat exchangers
Self-pressurizing sump concepts
Advanced oil routing mechanisms
Enhanced sealing technologies
Apply 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.