Sr. Staff Mechanical Engineer - BlueSky

About the role

The role offers significant hands-on involvement with CAD, structural analysis, materials, manufacturing, and mechanical integration. You will work closely with Engineering, Manufacturing, Quality, Supply Chain, and Program Management teams to deliver robust and production-ready systems.

Responsibilities

• Lead the mechanical design, analysis, and integration of complex systems and subsystems, including avionics packaging, structures, harnessing, connectors, and related hardware.
• Owning mechanical engineering deliverables throughout the product lifecycle, from concept development and prototyping through qualification, production, and field support.
• Develop detailed 3D CAD models, assemblies, engineering drawings, and manufacturing documentation while applying appropriate GD&T practices.
• Perform engineering calculations and analyses—including structural, stress, thermal, tolerance stack-up, fatigue, and FEA analyses as appropriate—to validate design performance and integrity.
• Select appropriate materials, manufacturing processes, and mechanical architectures to achieve performance, reliability, manufacturability, and cost objectives.
• Collaborate closely with Manufacturing, Quality, Supply Chain, Engineering, and Program Management to ensure designs are buildable, testable, maintainable, and reliable in demanding environments.
• Provide hands-on engineering support during testing, demonstrations, production activities, and field operations.
• Rapidly troubleshoot mechanical issues, conduct root cause investigations, and implement practical design fixes under tight schedules.
• Support integration activities and resolve cross-functional technical challenges to keep hardware development and delivery on track.
• Work with external suppliers and contract manufacturers when needed to support design execution, production, and technical issue resolution.
• Contribute to continuous improvement of mechanical design practices, engineering processes, and hardware development methods.

Requirements

• Bachelor’s degree in Mechanical Engineering or a closely related field from an accredited institution.
• 5–6 years of hands-on mechanical design experience in aerospace, ground support equipment, ruggedized hardware, or a closely related engineering environment.
• Strong proficiency with 3D CAD platforms such as SolidWorks, NX, CATIA, or similar tools, including experience creating detailed drawings and assemblies.
• Demonstrated knowledge of GD&T, structural design, material selection, and mechanical manufacturing processes.
• Experience performing engineering calculations and analyses related to stress, thermal performance, tolerance stack-ups, fatigue, and/or finite element analysis.
• Strong understanding of mechanical design principles and the ability to translate requirements into practical, reliable hardware solutions.
• Prominent experience collaborating cross-functionally with Manufacturing, Quality, Supply Chain, Engineering, and Program Management teams.
• Strong root cause analysis and structured problem-solving skills, with the ability to diagnose mechanical failures and implement effective corrective actions.
• Familiarity with engineering and manufacturing standards such as ASME, ISO, ASTM, or relevant industry-specific requirements.
• Familiarity with MIL-STD requirements and environmental qualification testing is preferred.
• Knowledge of power distribution, hydraulics, aerospace support systems, or related technologies is preferred.
• Experience working with external suppliers or contract manufacturers is an advantage.
• Comfortable working in a fast-paced, execution-focused environment where priorities can evolve and technical decisions may need to be made quickly.
• Strong communication, collaboration, ownership, and technical judgment skills.

Benefits

• Full remote, full-time employment.
• Annuar salary range of $240,000–$350,000, with actual compensation influenced by experience, skills, certifications, and work location.
• Performance bonus opportunity.
• Equity participation.
• Comprehensive employee benefits package.
• Opportunities to work on advanced aerospace and autonomous systems with real-world mission applications.
• A highly hands-on engineering environment with significant ownership across the product lifecycle.
• Collaboration with multidisciplinary engineering, manufacturing, quality, supply chain, and program teams.
• Opportunities to contribute to innovative hardware development from concept through field operations.