Bachelor's or Master's degree in Mechanical or Aerospace Engineering from an accredited U.S. institution (ABET)
10+ years of experience in aircraft mechanical design or structural modifications
Expert-level proficiency in PTC Creo Parametric modeling
Strong understanding of ASME Y14.x drafting standards and GD&T
Ability to perform classical structural/strength hand calculations
Experience with Windchill PLM workflows and configuration management
Ability to mentor junior engineers and manage complex tasks
Familiarity with manufacturing processes for sheet metal and machining
Responsibilities
Develop advanced 3D CAD models using PTC Creo, including complex geometries and large assemblies
Create and manage Technical Data Packages (TDPs) compliant with military and ASME standards
Perform mechanical and structural hand calculations for airworthiness documentation
Develop engineering drawings and analyses in support of airworthiness
Utilize PTC Windchill for configuration management and change-control workflows
Lead and mentor junior engineers on CAD standards and drafting practices
Apply manufacturing knowledge to optimize designs for fabrication and installation
Work independently on complex design tasks with minimal supervision
Benefits
401(k) plan with immediate 100% vesting and 4% discretionary match
Paid leave including PTO, holiday, bereavement, and military
Generous medical, dental, and vision insurance for employees and families
Health and dependent care FSA
Company-provided life/AD&D and supplemental life and disability insurance
TRICARE Supplement
Employee Assistance Program
Tuition assistance and professional development
Bonus programs
Full Job Description
ASI is seeking a highly skilled Senior Mechanical Design Engineer to support complex aircraft modification, prototyping, and integration projects within the Aircraft Prototype Systems Division (APSD). This position is located onsite at NAS Patuxent River, MD and is not remote eligible.
Responsibilities :
Develop advanced 3D CAD models using PTC Creo, including complex geometries, large assemblies, skeleton - based architectures, surfaces, and shrink-wrap techniques
Create, review, and manage Technical Data Packages (TDPs) compliant with MIL - STD - 31000 and ASME drafting standards including ASME Y14.100, Y14.24, Y14.35, and Y14.5 GD&T requirements
Perform classical mechanical and structural hand calculations for brackets, fasteners, margins of safety, and airworthiness substantiation to support flight clearance documentation
Develop engineering drawings, analyses, and documentation in support of airworthiness, referencing Mil - HDBK - 516, NAVAIRINST 13034.1, and NAWCADINST 13050.1
Utilize PTC Windchill for configuration management, product structure control (WTParts), CAD data management, and change - control workflows including ECPs and ECNs
Lead and mentor junior engineers and technicians, providing direction on CAD standards, GD&T, drafting practices, and workload prioritization
Apply manufacturing knowledge related to sheet metal and machining processes, including CNC, lathes, mills, press brakes, and water jets, ensuring designs are optimized for fabrication and installation
Work independently to execute complex, non - routine design tasks with minimal supervision, resolving technical issues and shaping engineering solutions on accelerated timelines
Required Qualifications:
Bachelor's or Master's degree in Mechanical or Aerospace Engineering from an accredited U.S. institution (ABET)
10+ years of experience in aircraft mechanical design, production support, or structural/mechanical modification work
Expert - level proficiency in PTC Creo Parametric modeling, including surfaces, skeletons, and large assembly management
Strong understanding and practical application of ASME Y14.x drafting standards and ASME Y14.5 GD&T
Ability to perform classical structural/strength hand calculations relevant to aircraft modifications
Demonstrated experience with Windchill PLM workflows and formal configuration - management processes
Ability to work independently, manage complex engineering tasks, and mentor junior team members
Familiarity with manufacturing processes to ensure designs are producible and installable in sheet - metal and machining environments
Strong communication skills and the ability to collaborate across multidisciplinary teams
Preferred Qualifications:
Experience designing, modifying, or qualifying aircraft weapon stores, launchers, and suspension equipment with familiarity with MIL - STD - 1760 and store - separation dynamics
Background in naval aviation repositories such as AVPLM, IETMS, or V - 22 technical data systems
Experience supporting or auditing AS9100D Quality Management Systems and developing SOPs or SWPs
FEA experience with ANSYS, Nastran, or similar tools for structural, thermal, or vibration analysis
Experience with additive - manufacturing design for prototyping or aircraft installation components
At ASI, we understand that everyone's journey is different. If you are not sure if your experience meets the requirements, we encourage you to apply. We are interested in what you have to offer.
Work Authorization/Security Clearance:
Must be a U.S. Citizen
Must qualify for a Secret Clearance
Benefits and Compensation:
401(k) plan with immediate 100% vesting and 4% discretionary match
Paid leave including PTO, holiday, bereavement, and military
Generous medical, dental, and vision insurance for employees and their families
Health and dependent care FSA
Company-provided life/AD&D, as well as supplemental life and disability insurance
