Mechanical Design Engineer

The Mechanical Design Engineer is responsible for the design, analysis, integration, and documentation of structural and mechanical systems associated with aircraft modifications, repairs, and certification programs.

This role combines the analytical responsibilities of a Mechanical Engineer with the CAD proficiency of a Mechanical Designer, independently developing complete engineering solutions from initial concept through released engineering data. The Mechanical Design Engineer develops structural installations, equipment mounts, aircraft modifications, engineering drawings, and supporting documentation while ensuring designs are structurally sound, manufacturable, maintainable, and compliant with applicable regulatory requirements.

Mechanical Design Engineers work closely with Electrical Engineers, Certification Engineers, Stress Analysts, Production personnel, and external stakeholders to develop engineering solutions that meet technical, regulatory, and operational requirements. They are expected to independently produce and maintain the engineering data necessary to support fabrication, installation, certification, and continued airworthiness.

What You Will Be Doing

• Design, analyze, and document aircraft structures, mechanical systems, equipment installations, and aircraft modifications supporting repair, alteration, and certification programs.
• Develop complete engineering solutions that satisfy customer requirements, regulatory requirements, airworthiness standards, and program objectives.
• I ndependently develop, revise, and maintain 3D CAD models, engineering drawings, and supporting engineering documentation in accordance with company standards and ASME Y14.5.
• Develop and maintain Bills of Materials (BOMs), engineering documentation, and associated design data under configuration control.
• Perform engineering analyses including structural, thermal, vibration, fatigue, and other evaluations necessary to support design decisions and certification activities.
• Coordinate with engineering, certification, production, quality, program personnel, vendors, and customers to develop complete engineering solutions and data packages.
• Support development of certification artifacts, compliance substantiation, engineering reports, test plans, and supporting documentation required for regulatory approval.
• Evaluate manufacturability, maintainability, serviceability, installation considerations, and lifecycle impacts throughout the design process.
• Provide technical support during fabrication, assembly, installation, troubleshooting, testing, and aircraft modification activities.
• Participate in engineering design reviews and provide technical recommendations regarding safety, performance, reliability, maintainability, and regulatory compliance.
• Maintain engineering data under configuration control and ensure work products comply with company standards, procedures, and drawing practices.
• Support continuous improvement initiatives, development of engineering standards, modeling practices, and lessons-learned activities.
• Perform other duties as assigned by the Engineering Manager.

You Must Have

• Bachelor's degree in Mechanical Engineering, Aerospace Engineering, or a related engineering discipline from an accredited college or university.
• Experience designing, analyzing, integrating, and documenting aircraft structures, mechanical systems, equipment installations, or aircraft modifications.
• Professional (CSWP) certification in SolidWorks or higher, or demonstrated equivalent professional proficiency using SolidWorks for development of production-quality engineering data.
• Proficiency using SolidWorks for 3D modeling, assemblies, sheet metal, drawing creation, and design documentation.
• Working knowledge of engineering principles, ASME Y14.5 (GD&T), materials, manufacturing processes, and mechanical system integration.
• Experience creating engineering drawings, Bills of Materials (BOMs), technical reports, specifications, and supporting engineering documentation.
• Familiarity with FAA regulations, aircraft certification processes, STC projects, or FAA Form 337 major alteration processes.
• Proficiency with Microsoft Office applications and strong analytical, troubleshooting, organizational, and communication skills.
• Ability to coordinate effectively with Engineering, Certification, Production, Quality, Program Management, vendors, and customers.
• Ability to work in both office and aircraft hangar environments.
• U.S. Citizenship or Permanent Resident status.

Nice To Haves

• Five or more years of experience supporting aircraft modification, repair, integration, or aerospace product development programs.
• Experience independently developing complete engineering solutions from concept through implementation, including relevant engineering reports, substantiation documents, installation instructions, test procedures, and certification support documentation.
• SolidWorks Certified Expert (CSWE) certification and/or additional CSWPA specialty certifications (Sheet Metal, Drawing Tools, Weldments, Surfacing, etc.).
• Experience supporting FAA certification activities, including STC programs, compliance documentation, test plans, test reports, and Instructions for Continued Airworthiness.
• Familiarity with MIL-HDBK-516C airworthiness requirements and military aircraft modification programs.
• Experience performing structural, thermal, vibration, fatigue, or other engineering analyses supporting design and certification activities.
• Experience with aircraft production, modification, installation, ground testing, or flight test support.
• Experience supporting reverse engineering, 3D scanning, and CAD model development from scan data.
• Familiarity with configuration management, engineering release processes, and aerospace quality systems such as AS9100.