Principal Mechanical Design Engineer

Minimum Clearance Required: None. Must be able to obtain a Secret clearance. Employee background check required.

About the Role

The Principal Mechanical Design Engineer provides strategic leadership in the design, development, and implementation of advanced mechanical and aerospace systems for DoD and industrial applications. This role focuses on driving innovation, solving complex engineering challenges, and shaping organizational capabilities. Engineers at this level are responsible for high-level technical oversight, mentoring, and contributing to business growth through thought leadership and client engagement.

Responsibilities

• Lead the conceptualization, design, and development of cutting-edge mechanical and aerospace systems, components, and processes for mission-critical applications such as ground vehicles, aircraft, armaments, and advanced materials.
• Oversee the creation of highly complex CAD models and manufacturing drawings using software such as Creo, SolidWorks, or AutoCAD, ensuring compliance with GD&T and DoD standards.
• Direct advanced engineering analyses, including Finite Element Analysis (FEA), computational modeling, and system optimization, to solve complex technical challenges.
• Identify and implement innovative technologies, methodologies, and processes to advance organizational capabilities and meet emerging client needs.
• Provide high-level oversight for prototype manufacturing efforts, including strategic planning, documentation, and coordination with internal teams and external vendors.
• Develop and approve advanced testing protocols to validate designs, ensuring compliance with performance expectations, safety regulations, and project-specific requirements.
• Analyze test results, identify systemic issues, and implement strategic design modifications to optimize system performance and reliability.
• Serve as the primary technical authority for large-scale, multidisciplinary projects, providing strategic guidance and resolving complex engineering challenges.
• Collaborate with executive leadership, clients, and stakeholders to define project requirements, deliverables, and success metrics.
• Represent the organization as a technical expert in client engagements, industry conferences, and strategic discussions.
• Mentor and develop engineers across all levels, fostering technical excellence and professional growth.
• Lead technical reviews, establish best practices, and drive knowledge-sharing initiatives to enhance organizational capabilities.
• Shape the strategic direction of the engineering division by contributing to long-term planning and innovation efforts.
• Drive business growth through thought leadership, proposal development, and strategic client engagement.
• Ensure all designs, processes, and deliverables comply with DoD standards, safety regulations, and project-specific requirements.
• Identify opportunities for innovation, process improvement, and new business ventures to expand organizational impact.
• Work closely with clients and project teams, interact with vendors and subcontractors, and mentor lower-level staff.

Requirements

• Bachelor’s Degree in Mechanical, Aerospace, Electrical, Systems, or Materials Engineering. Master’s degree strongly desired.
• 10+ years of relevant experience in mechanical or aerospace engineering, including leadership and strategic oversight.
• Advanced proficiency in CAD software such as Creo, SolidWorks, or AutoCAD, with experience creating highly complex parametric models and assemblies.
• Working knowledge of Finite Element Analysis and Inspection Software such as ANSYS, ABAQUS, or Polyworks.
• Expertise in engineering principles, including GD&T, tolerance stack-ups, manufacturing processes, and system optimization.
• Proven ability to lead large-scale, multidisciplinary teams and manage complex projects effectively.
• Exceptional problem-solving skills and attention to detail.
• Strong written and oral communication skills, with the ability to present technical findings to executive leadership and external stakeholders.
• Strong background in research and development, requirements development, mechanical and systems design, manufacturing processes, and equipment development/specification.
• Experience with implementation of processes in an industrial production environment.
• Experience in performance-based marketing, business growth, and proposal development (technical task planning, scheduling, and cost estimating).
• Proficiency at maintaining task execution plans, preparing reports, and presentations.

Preferred Qualifications

• Familiarity with reverse engineering techniques, computational modeling, and rapid prototyping processes.
• Significant experience in the defense industry or government contracting.
• Proven track record of mentoring and developing engineering teams across all levels.

Benefits

• Competitive salary and benefits package.
• Exceptional career growth opportunities.
• Access to cutting-edge technology and educational opportunities.
• Recognition for quality work.
• Work-life balance initiatives.

About Us

CTC Engineering and Manufacturing specializes in transforming cutting-edge technologies into real-world solutions. We harness the power of 3D printing, advanced joining techniques like friction stir welding, and cutting-edge design tools to tackle complex challenges for a diverse set of clients. At CTC, you’ll master the future of manufacturing, innovate for impact, work alongside a passionate team of engineers and scientists, and leave your mark on critical missions.