Mechanical Engineer, Sr.

We’re looking for a hands-on Senior Mechanical Engineer to lead and support the mechanical design, testing, and production of electrical machines and electronics packaging for high-altitude aerospace applications.

About the role

You will drive the mechanical packaging of electronic equipment that must survive extreme mass, volume, thermal, and vibration environments. You will also manage mid-size development projects outsourced to sub-contractors, from system-level requirements through production.

Responsibilities

• Lead or support thermal, structural, dynamic, and fluid-flow analysis for electronics equipment.
• Design, model, and select materials for mechanical devices.
• Perform stress, fatigue, and thermal analysis; select bonding materials for extreme conditions.
• Develop mechanical drawings with precise dimensional tolerances.
• Create assembly instructions, test procedures, and test plans to verify designs.
• Conduct laboratory and field testing; collect and analyze data.
• Coordinate activities of other engineers and technicians to meet schedules and milestones.
• Develop subsystem requirements specifications per MIL-STD 961D or equivalent.
• Oversee outsourced development of systems, equipment, or components.

Requirements

• Minimum 8–12 years of relevant mechanical engineering experience, including at least 5 years in production rotating electrical machines, electronics packaging, or mechanical devices for aerospace/industrial applications.
• Proficiency with SolidWorks (mechanical modeling), ANSYS (structural/fatigue), and ANSYS Icepack (thermal).
• Extensive experience designing high-performance electrical rotating machines and thermal-management solutions.
• Experience with adhesives and bonding techniques for extreme environments.
• Experience with manufacturing methodologies for electrical machines.
• Experience creating and maintaining product document trees and bills of materials (BOM).
• Experience with test and measurement techniques (e.g., torque transducer calibration, instrumentation).
• Familiarity with MIL-STD-810 or DO-160 and MIL-STD 961D (or equivalent) for subsystem specifications.

Qualifications

• MS in Mechanical Engineering preferred.
• Senior membership or higher in a reputable international engineering society (e.g., ASME) is a plus.
• Ability to work independently, solve complex problems, and communicate technical concepts to non-technical staff.
• Strong initiative, ownership, and drive to meet company objectives in a fast-paced, deadline-driven environment.
• Commitment to continuous improvement and learning from mistakes.
• Excellent interpersonal, analytical, and written/verbal communication skills.
• Focus on teamwork and collaboration.

Physical Demands

• Ability to work in both office and production environments.
• Frequent sitting, standing, talking, hearing, and use of hands/fingers to operate computers and telephones.

Pay

$111,500 – $170,000 per year. Final offer depends on location, role, experience, education, and key skills.

Benefits

• Medical, dental, and vision coverage.
• 401K with company matching.
• 9/80 work schedule (every other Friday off).
• Paid holiday shutdown.

This position requires compliance with International Traffic Arms Regulations (ITAR) and/or Export Administration Regulations (EAR). Applicants must qualify as a U.S. person (U.S. citizen, lawful permanent resident, refugee, or asylee) or be eligible for an export license. Some roles may require current U.S. citizenship due to contract requirements.