The Senior Mechanical Design Engineer leads the design, development, and integration of complex aerospace mechanical components and assemblies. This role is responsible for delivering technically robust, manufacturable, and compliant designs for flight hardware, structures, enclosures, mechanisms, and electromechanical subsystems. Operating with minimal supervision, the engineer plays a key role in system architecture decisions, cross-functional integration, and mentoring of junior engineers. The role supports the full product lifecycle from concept through production and qualification.
Key Responsibilities:
Lead the design and development of aerospace-grade mechanical components and assemblies (e.g., brackets, housings, thermal structures, deployment mechanisms)
Own mechanical architecture decisions, interface control, and critical-to-function features for assigned subsystems
Generate and validate detailed 3D models, engineering drawings, and GD&T callouts per ASME Y14.5
Perform or review stress/thermal/kinematic analyses and interface with analysis teams on validation
Ensure designs meet system-level requirements for strength, mass, thermal performance, vibration, and manufacturability
Collaborate with electrical, systems, manufacturing, and test engineering to ensure full lifecycle integration
Participate in and lead PDRs, CDRs, and MRBs; support design justification, trade studies, and failure analyses
Serve as a technical liaison for suppliers, internal build teams, and quality engineering
Support environmental testing and post-test design iterations or failure investigations
Mentor junior and mid-level engineers; promote design standards, best practices, and knowledge sharing
Drive continuous improvement of design tools, methods, and documentation processes
Key Focus Areas:
Mechanical ownership of complex aerospace subsystems or product lines
Precision design under tight mass, volume, and environmental constraints
Mechanical systems integration with avionics, propulsion, thermal, or structural platforms
Design review leadership, peer mentoring, and high-level collaboration
Supplier and manufacturing interface for critical flight components
Qualifications & Skills:
Education:
Bachelor’s degree in Mechanical or Aerospace Engineering required
Master’s degree preferred, especially for high-performance or flight-critical hardware
Certifications (Preferred):
GD&T Certification (ASME Y14.5)
CATIA, NX, Creo, or SolidWorks advanced certification
Six Sigma Green/Black Belt or DFSS
PE license or equivalent engineering registration
Experience:
7–12+ years of mechanical design experience, preferably in aerospace, defense, or space systems
Proven track record of owning full mechanical subsystems from concept through production or launch
Deep knowledge of aerospace materials (titanium, aluminum, composites), joining techniques, and structural/thermal interfaces
Experience with configuration management, ECN processes, and high-reliability requirements
Hands-on exposure to test campaigns (vibration, thermal, shock, life cycle, etc.) and qualification processes
Technical Skills:
Expert in 3D CAD (Creo, NX, CATIA) and engineering drawing practices
Strong understanding of structural design principles, load paths, vibration isolation, and mechanisms
Familiarity with FEA tools and ability to interpret analytical results to drive design changes
Proficient in PLM/PDM tools (Windchill, Teamcenter) and documentation practices
Soft Skills:
Technically authoritative with strong leadership presence and problem-solving mindset
Excellent communicator—able to articulate design rationale and interface with leadership, customers, and teams
Self-motivated, adaptable, and able to manage multiple projects in dynamic environments
Committed to mentorship, quality engineering, and continuous technical improvement