Senior Mechanical Engineer

Overview The Senior Mechanical Engineer is responsible for the design, analysis, and development of complex mechanical systems from concept through production release. In this role, you will lead the detailed mechanical design of products and subsystems, perform advanced engineering analyses, and ensure designs meet performance, reliability, and manufacturability requirements. You will work closely with cross-functional teams including Electrical, Software, Manufacturing, Quality, and Supply Chain to deliver robust, production-ready solutions. This position requires strong hands-on design experience combined with deep analytical capability in structural FEA, vibration and modal analysis, and heat transfer, as well as practical expertise in injection-molded plastic design and production manufacturing processes. Experience: 10+ years Education: BS or MS in Mechanical or Aerospace Engineering Key Duties Own the mechanical design and detailed implementation of product subsystems from concept through sustainingDevelop and maintain mechanical system architectures, layouts, and detailed component designsPerform advanced structural analysis (FEA) to validate strength, stiffness, fatigue, and durability requirementsConduct vibration and modal analysis to evaluate dynamic response, resonance, and environmental loadingPerform thermal and heat transfer analysis to ensure safe and reliable operation under all operating conditionsTranslate high-level product requirements into clear, traceable mechanical requirements and design solutionsLead design trade studies to down-select materials, architectures, and manufacturing processesDesign for injection molding, including part geometry, draft, gating considerations, tolerances, and material selectionApply DFM/DFA and DFT best practices to optimize cost, quality, and manufacturabilityCreate and maintain accurate CAD models, drawings, and GD&T using SolidWorks or equivalent CAD toolsSupport prototype builds, testing, and design iteration based on verification and validation resultsCollaborate with suppliers and contract manufacturers to review designs, tooling, and production readinessSupport root-cause analysis and corrective actions for test, quality, or manufacturing issuesMentor junior engineers and provide technical guidance on best design and analysis practicesMaintain mechanical documentation and bills of materials (BOMs) within the PLM system throughout the product lifecycle Key Background Knowledge Strong experience in mechanical system and component design for complex productsDemonstrated expertise in structural FEA, vibration analysis, and modal testing correlationSolid understanding of heat transfer and thermal management in electromechanical systemsProven experience designing injection-molded plastic components for high-volume productionExperience with metals, plastics, fasteners, adhesives, and surface treatmentsProficiency in SolidWorks, PDM, and PLM systemsExperience working with test teams to correlate analysis results with physical testingDemonstrated ability to work effectively across cross-functional teams and influence technical decisionsStrong documentation, communication, and technical leadership skillsProficient understanding of engineering principles, best practices, and design processesExperience supporting products through production ramp and sustaining engineering Preferred Qualifications Familiarity with supplier tooling reviews and injection mold qualificationPrevious experience with avionics or UAVsExperience with propulsion systems (propeller design and motor selection) Background Check This position will require successfully completing a post-offer background check. Qualified candidates with a criminal history will be considered and are not automatically disqualified, consistent with federal and state law. EEO and ITAR/EAR Work Authorization Disclosure Red Cat Holdings provides equal employment opportunities (EEO) to all employees and applicants for employment and prohibits discrimination and harassment of any type without regard to race, color, religion, age, sex, national origin, disability status, genetics, protected veteran status, sexual orientation, gender identity or expression, or any other characteristic protected by federal, state or local laws. This position requires direct or indirect access to hardware, software, technology or technical data controlled under the International Traffic in Arms Regulations (ITAR) and the Export Administration Regulations (EAR). Successful candidates for positions subject to ITAR/EAR restrictions must provide proof of U.S. Citizenship or Permanent Residence and must not require sponsorship for export-restricted work authorization. E-Verify The company participates E-Verify ensure eligibility for employment and compliance with Right to Work rules.