Mechanical Systems Engineer

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The Lead Mechanical Systems Engineer is responsible for end‑to‑end ownership of mechanical system design for small uncrewed propulsion engines, with primary focus on lubrication systems, bearing architectures, and limited‑life engine design. The role spans conceptual design through qualification, ensuring designs meet Safety, Quality, Delivery, and Cost (SQDC) objectives and program requirements. You will work with both remote (Jupiter, FL) and local teams (Evendale, OH).

• Mechanical Systems Ownership (Concept to Qualification):
  Lead mechanical system architecture, requirements flow‑down, and verification plans for lube systems, bearings, and limited‑life components from trade studies through qualification test.
• Lubrication Systems:
  Define system requirements; size pumps, jets, passages; select fluids; design scavenge and filtration; complete thermal management analyses; and own FMEAs and fault response strategies.
• Bearing Design:
  Architect bearing selections and life calculations; establish preload, fits, lubrication regimes; support rotordynamic and thermal analyses; validate via rig or engine testing and data correlation.
• Limited‑Life Engine Design:
  Develop design rules and margins tailored to mission profiles; set inspection/retirement intervals; drive affordability and manufacturability for targeted life limits while safeguarding safety.
• Analysis and Validation:
  Execute and review hand‑calc and model‑based analyses (rotor dynamics, tribology, CFD/thermal, reliability); plan and oversee rig/engine testing; define qualification criteria and evidence.
• Integration and V&V:
  Lead requirements management, DFMEA/FMECA and traceability; ensure interfaces with airframe, controls, and manufacturing are robust; resolve non‑conformances and execute RCCA.
• Standards and Compliance:
  Apply relevant aerospace, safety, and export control requirements; define design standards and best practices; ensure configuration control and documentation quality.
• Program Execution:
  Build schedules, manage risks, and drive deliverables across design gates; support supply‑chain and supplier technical management; contribute to proposals, ROMs, and design‑to‑cost tradeoffs.
• Continuous Improvement:
  Identify and implement process improvements across design, analysis, and test workflows; mentor early‑career engineers; promote a culture of safety, quality, and learning following FLIGHT DECK standards.

• Education/
  
  Experience:
  
  BS in Mechanical/Aerospace Engineering (MS preferred) with at least 3 years’ experience in turbo machinery or small propulsion systems; demonstrated ownership from concept to qualification.
• Technical Depth:
  Expertise in lubrication systems and bearing design for high‑speed rotating machinery; proficiency with rotor dynamics, tribology, thermal analysis, and reliability engineering.
• Leadership & Communication:
  Proven technical leadership, cross‑functional collaboration, supplier engagement, and clear communication of technical decisions, risks, and trade‑study outcomes.
• Legal authorization to work in the U.S. is required. We will not sponsor individuals for employment visas, now or in the future, for this job opening.

• Tools:
  Experience with CAD/PLM, rotodynamic/thermal analysis tools, CFD/FEM familiarity, requirements management, and data analysis from rig/engine testing.
• 5 years experience module support.

• Safety:
  Zero escape defects in lube/bearing designs; robust hazard analysis and mitigation documented and validated.
• Quality:
  First‑time‑right design reviews; qualification evidence fully meeting requirements with minimal re‑test.
• Delivery:
  On‑time execution of design gates, test readiness, and qualification milestones.
• Cost:
  Achieve design‑to‑cost targets through smart architecture choices, supplier optimization, and limited‑life strategy.

• Internal:
  Systems, thermal/fluids, structures, rotor dynamics, controls, manufacturing, test & instrumentation, reliability.
• External:
  Suppliers (bearings, pumps, filters, seals),…