Senior Mechanical Design Engineer – Aerospace Hardware

Key Responsibilities

• Lead end-to-end hardware development for AERO mobile solution, from conceptual design through production and in-service operation
• Interact with various stakeholders
• Own design, HW verification and qualification testing, production ramp up and field deployment
• Define design criteria, collaborate cross-functionally to refine requirements, and drive system-level optimization
• Perform engineering analyses using hand calculations, FEA, CFD, and CAD tools in a fast-paced, iterative environment
• Rapidly develop and refine design solutions to support system trade studies and influence overall product direction
• Lead design reviews and partner with internal certification team to qualify components and systems
• Develop detailed production drawings using GD&T and conduct tolerance stack-up analyses to ensure manufacturability and performance
• Drive design for manufacturability (DFM), simplifying designs, reducing part and process count, and implementing robust error-proofing strategies
• Plan and execute environmental and performance testing to validate designs and ensure compliance with requirements
• Own product delivery timelines across all phases—concept, design, build, and service—while driving continuous improvements in reliability and performance

Basic Requirements

• Skills, Experience and Requirements
• Bachelor's degree in mechanical engineering, aerospace engineering, or related technical field
• 6+ years of experience with mechanical/electromechanical design, analysis, testing, and/or manufacturing

Preferred Qualifications

• Strong foundation in mechanical engineering principles, including statics, dynamics, thermodynamics, and materials
• Proven experience in hardware design and development for complex systems, preferably in aerospace or similar high-reliability environments
• Proficiency in CAD tools (e.g., Creo, Solidworks etc.) and engineering analysis methods including FEA and CFD (e.g. Flotherm, FloEFD etc.)
• Experience performing hand calculations and validating designs through analytical and simulation approaches
• Experience with electronic board assembly design, including mechanical integration, mounting strategies, and thermal management solutions
• Working knowledge of electronics design across chip-level, package-level, and board-level integration
• Deep understanding of GD&T and tolerance stack-up analysis for production-ready designs
• Knowledge of design for manufacturability (DFM) and design for assembly (DFA) principles
• Familiarity with FAA certification processes and working with regulatory standards (e.g., DO-160, FARs)
• Experience conducting environmental and performance testing, including validation and verification methods
• Strong problem-solving skills with the ability to work effectively in fast-paced, iterative development environments
• Excellent communication and collaboration skills, with experience working across multidisciplinary teams (electrical, RF, EMC, manufacturing)
• Ability to manage multiple priorities and own product development timelines from concept through production
• Strong attention to detail, with a focus on reliability, performance, and continuous improvement
• Experience with aircraft systems or avionics hardware integration
• Familiarity with RF, EMI/EMC considerations in hardware design
• Experience supporting high-rate production environments or in-house manufacturing lines
• Knowledge of supply chain, production processes, and lifecycle management

Salary Range

Compensation: $100,500.00/Year - $134,000.00/Year

Benefits

We offer versatile health perks, including flexible spending accounts, HSA, a 401(k) Plan with company match, ESPP, career opportunities, and a flexible time away plan; all benefits can be viewed here: EchoStar Benefits.