Sr Mechanical Design Engineer

Responsibilities

• Lead the design of aerospace mechanical and electromechanical products from concept through production.
• Design rugged electronic enclosures, thermal management hardware, structural assemblies, and precision mechanical components.
• Perform engineering trade studies balancing performance, weight, manufacturability, reliability, and cost.
• Develop tolerance analyses, mechanical interfaces, fits, and assembly strategies.
• Perform structural analysis using Analytical calculations and FEA to evaluate stress, vibration, fatigue, thermal effects, and structural integrity.
• Develop margins of safety and correlate analytical models with test results.
• Evaluate materials, fasteners, sealing methods, and mechanical interfaces.
• Support all phases of product development including requirements, design reviews, detailed design, prototype builds, qualification testing, and production transition.
• Develop engineering documentation, manufacturing drawings, and design packages using SolidWorks and ASME Y14.5 GD&T.
• Support Engineering Change Notices (ECNs) and configuration management activities.
• Design products to meet military and aerospace environmental requirements including vibration, shock, thermal cycling, altitude, humidity, and corrosion.
• Integrate electronics, wiring, connectors, thermal management hardware, and mechanical structures into compact aerospace products.
• Incorporate design practices supporting EMI/EMC, grounding, shielding, environmental sealing, and thermal management.
• Support DFM/DFA activities, prototype builds, qualification testing, and production.
• Work with Manufacturing, Quality, Suppliers, and Test Engineering to resolve technical issues and improve product performance.
• Mentor junior engineers and support technical proposals and engineering estimates.

Requirements

• Bachelor's degree in Mechanical Engineering.
• Minimum 7 years of mechanical design experience developing aerospace, defense, or other high-reliability products.
• Experience designing complex mechanical or electromechanical assemblies from concept through production.
• Proficiency with SolidWorks (or equivalent 3D CAD) and ANSYS Mechanical (or equivalent FEA).
• Strong understanding of structural analysis, mechanics of materials, fatigue, vibration, tolerance analysis, materials, fasteners, and environmental sealing.
• Experience creating manufacturing drawings compliant with ASME Y14.5.
• Strong analytical, communication, and problem-solving skills.
• U.S. Citizenship required.

Preferred Qualifications

• Master's degree in Mechanical or Aerospace Engineering.
• Experience with rugged electronic packaging and aerospace enclosure design.
• Experience supporting MIL-STD-810, DO-160, or equivalent environmental qualification programs.
• Familiarity with EMI/EMC design practices, thermal management, pressure vessels, fluid systems, or refrigeration systems.
• Experience supporting prototype builds, qualification testing, and production transition.
• Experience with configuration management and engineering release processes.

Desired Characteristics

• Strong engineering judgment and hands-on problem-solving skills.
• Able to independently own mechanical work packages from concept through production.
• Effective collaboration across multidisciplinary engineering teams.
• Self-motivated with a commitment to technical excellence, quality, and continuous improvement.