Mechanical Design Engineer, Senior

Overview

The Mechanical Design Engineer, Senior will lead the design, analysis, development, and production release of complex mechanical components and assemblies.

Responsibilities

Develop 3D parametric models, detailed part drawings, and assembly drawings in SolidWorks from concept through production release.

Produce engineering drawings with complete GD&T per ASME Y14.5, including dimensions, tolerances, datum schemes, and surface finish callouts suitable for fabrication and inspection.

Perform tolerance stack-up analyses (worst-case and statistical) to verify fit, function, and assembly feasibility prior to release.

Conduct structural, modal, and thermal finite element analyses (FEA) to validate mechanical designs against load, vibration, shock, and thermal-environment requirements.

Select materials, fasteners, and commercial-off-the-shelf components based on mechanical, environmental, manufacturing, and cost requirements.

Apply Design for Manufacturability (DFM) and Design for Assembly (DFA) principles in collaboration with manufacturing and supplier-quality teams to reduce cost and assembly risk.

Lead prototype build, design verification testing, and iterative refinement of mechanical designs to validate performance prior to production.

Prepare and present designs at preliminary and critical design reviews (PDR, CDR), incorporating peer and stakeholder feedback into the released baseline.

Author engineering change proposals and engineering change notices (ECP/ECN) and maintain mechanical design baselines under formal configuration management.

Collaborate with electrical, systems, and software engineering, as well as manufacturing and test, to ensure mechanical interfaces meet program requirements.

Provide technical leadership on mechanical design efforts, establish design standards and best practices, and mentor less experienced engineers.

Other duties as assigned.

Minimum Qualifications & Education Requirements and Desired Skillsets

Bachelor's degree in Mechanical Engineering, Aerospace Engineering, or a closely related discipline from an accredited institution.

10+ years of demonstrated mechanical design experience, preferably in defense, aerospace, or comparable regulated industry.

Proficiency in SolidWorks, including assembly modeling and detailed drawing creation.

Strong working knowledge of GD&T per ASME Y14.5 and the ability to apply tolerance schemes that meet inspect ability and producibility requirements.

Experience performing FEA using SolidWorks Simulation and interpreting results to drive design decisions.

Experience performing tolerance stack-up analyses to validate mechanical fit and function.

Working familiarity with common manufacturing processes (machining, sheet metal, casting, additive manufacturing) and their design implications.

Demonstrated experience leading mechanical design efforts and mentoring less experienced engineers.

Strong written and verbal communication skills, with the ability to interact effectively with all stakeholders.

A self-starter, team player with a desire to work with a team of engineers, integrators, analysts, and others in a dynamic and fast-paced environment.

U.S. Citizenship with Active Secret Security clearance and ability to maintain required clearance.

Physical Description

Employees in these positions will function in a general office/cubicle setting environment, and laboratory/testing setting using standard office equipment and various electronic testing equipment, including a computer, telephone, printers, video equipment, computer software and testing equipment. Will interact in a general office setting environment with various personnel; participate in meetings and contribute to team success; deliver timely results and produce reports; receive and communicate information; may include telework. May function in a specialized laboratory/testing environment using electronic testing equipment, computer software and complex systems. May move and test equipment of various weights. Laboratory environment may require use of protective equipment (PPE) including but not limited to safety glasses and protective hearing and footwear. May be expected to work varying shifts and hours to ensure successful operation of activities in the organization due to business demands; travel occasionally for assigned work.