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Project Overview We're developing a linear actuator system with a magnetically-coupled drive mechanism. We need an experienced mechanical engineer to design an adjustable air gap magnetic sleeve bearing that allows end-users to tune coupling strength for varying load conditions. Technical Challenge Our system uses: Internal carriage driven by 6mm lead screw (1-meter travel range) External sleeve bearing, magnetically coupled to the internal carriage Multi-pole magnetic array providing the coupling force The Design Problem: We need a user-adjustable mechanism to change the air gap between internal and external magnet arrays by 1-3mm, providing 2-4x range in coupling force. This must accommodate: Three adjustment settings for different load profiles Tool-free or simple adjustment accessible to end-users Maintain gap consistency throughout full travel range over 1000+ cycles Intentional slip capability/override at a calibrated force threshold Deliverables CAD model (Fusion) of the complete adjustable coupling assembly Engineering drawings with tolerances and GD&T specifications Bill of materials with commercial sourcing recommendations Force calculations showing coupling strength vs. gap distance for provided magnet specifications DFM analysis for overseas contract manufacturing Technical Requirements Integration with existing actuator architecture (dimensions provided under NDA) Adjustment mechanism: threaded ring, eccentric cam, detent system, or similar Locking to maintain adjustment setting during operation Material selection optimized for low-friction, durability, cost, and manufacturability Target: adjustment range providing 50N to 150N tangential force variation Constraints Compact form factor required Consumer product cost targets (high-volume manufacturing) Assembly-friendly design for automated or semi-automated production Ideal Candidate Required: 5+ years mechanical design experience in actuators, robotics, or automation Required: Experience with magnetic coupling, adjustment mechanisms, or precision mechanical systems Required: CAD proficiency (Fusion strongly preferred) Preferred: DFM experience for Asian manufacturing (China/Mexico supply chain) Preferred: Consumer product design with cost optimization focus Preferred: FEA experience for magnetic field analysis