Senior Mechanical Engineer

The Senior Mechanical Engineer will lead the design, analysis, testing, and production of mechanical systems and electronics packaging used in high‑altitude aerospace applications. This role focuses on developing mechanically robust, thermally efficient solutions for rotating electrical machines and electronic equipment, ensuring they meet stringent environmental and performance requirements. The engineer will also manage mid‑size development projects and collaborate with internal teams and external subcontractors.

• Lead or support thermal, structural, dynamic, and fluid‑flow analyses for electronics equipment.
• Conduct laboratory and field testing, including data acquisition and documentation.
• Model mechanical components and assemblies; select appropriate materials for performance and manufacturability.
• Perform stress, fatigue, and thermal analyses; select and validate bonding materials.
• Create detailed mechanical drawings and define dimensional tolerances.
• Develop assembly instructions, test plans, and test procedures.
• Verify designs through structured testing and analysis.
• Solve complex technical challenges requiring deep understanding of variable mechanical and environmental factors.
• Execute project assignments according to schedules, milestones, and available resources; may act as Team Lead or coordinate activities of other personnel.
• Perform additional related duties as required.

• 8–12 years of relevant experience in mechanical engineering.
• At least 5 years supporting production development of rotating electrical machines, electronics packaging, and/or mechanical solutions for industrial or aerospace applications.
• Experience developing subsystem requirements in accordance with MIL‑STD‑961D or equivalent.
• Proficiency with CAD/CAE tools required for the role:
• Solid Works (mechanical modeling)
• ANSYS (structural and fatigue analysis)
• ANSYS Icepak (thermal analysis)
• Extensive experience designing rotating electrical machines for high‑performance applications.
• Strong background in thermal management, material properties, and environmental trade‑offs.
• Experience with bonding techniques suitable for extreme conditions.
• Knowledge of manufacturing methods for electrical machines.
• Experience creating and maintaining product document trees and Bills of Materials (BOMs).
• Hands‑on experience with mechanical testing and instrumentation (e.g., torque transducer calibration).

• Master’s degree in Mechanical Engineering.
• Senior‑level or higher recognition by a professional engineering society (e.g., ASME).
• Familiarity with MIL‑STD‑810, DO‑160, and MIL‑STD‑961D.
• Ability to independently apply advanced engineering principles to complex problems.
• Strong communication skills with ability to present concepts to technical and non‑technical audiences.
• Demonstrated success in fast‑paced, cross‑functional environments with broad responsibilities.
• Strong initiative, ownership, and commitment to continuous improvement.
• Excellent problem‑solving, analytical, interpersonal, and written communication skills.
• Team‑oriented mindset with a focus on collaboration and shared success.