Senior Mechanical Systems Engineer (Aircraft Modifications & Interiors)

Position Summary

Design and develop complex aircraft modifications and installations related to mechanical systems, including air conditioning, ventilation, smoke detection, equipment cooling, oxygen, potable water, wastewater, vacuum waste, and refrigerant systems. Responsible for ensuring designs meet customer requirements, quality standards, FAA regulations, project schedules, and budget objectives using industry-standard CAD tools.

Key Responsibilities

• Design and develop complex mechanical system installations and aircraft modifications.
• Create system architectures, schematics, and installation designs that satisfy functional and regulatory requirements.
• Analyze and interpret subsystem specifications, engineering requirements, and project documentation.
• Select appropriate materials based on performance, structural, environmental, and certification requirements.
• Collaborate with suppliers to evaluate components and conduct material testing when necessary.
• Partner with Manufacturing Engineering teams to optimize designs for manufacturability, assembly efficiency, cost reduction, and quality improvement.
• Develop and maintain Bills of Materials (BOMs), assembly documentation, and fabrication specifications.
• Ensure designs comply with customer requirements, FAA regulations, and applicable industry standards.
• Support engineering projects while maintaining schedule and budget commitments.
• Provide technical leadership, guidance, and mentorship to junior engineering staff.
• Serve as liaison engineering support for production and installation teams.
• Support aircraft testing activities, including test preparation, test plan development, and test report generation.
• Research and implement innovative solutions to complex engineering challenges.
• Participate in design reviews, troubleshooting efforts, and continuous improvement initiatives.
• Perform additional duties as assigned.

Desired Competencies

Professional Skills

• Adaptability and flexibility in a fast-paced engineering environment.
• Strong verbal and written communication skills.
• High level of accountability and dependability.
• Self-motivated with strong initiative and problem-solving abilities.
• Collaborative team player with a customer-focused mindset.
• Commitment to quality, accuracy, and continuous improvement.

Engineering Competencies

• Strong engineering judgment and decision-making skills.
• Effective planning, prioritization, and organizational abilities.
• Deep technical knowledge of aircraft mechanical systems and design practices.
• Ability to manage multiple projects while maintaining attention to detail.
• Strong analytical and troubleshooting skills.

Education & Experience

• Bachelor's Degree in Aerospace Engineering, Mechanical Engineering, or a related discipline.
• Minimum of 8 years of relevant aerospace engineering experience.
• Aircraft interiors, aircraft modification, or aviation systems experience required.
• Equivalent combination of education and experience may be considered.

Export Control Requirement

Must qualify as a U.S. Person under applicable export control regulations (ITAR).

Required Technical Skills

Design & CAD

• Strong 3D CAD design experience (Inventor preferred).
• Proficiency with AutoCAD or equivalent 2D drafting platforms.
• Ability to generate, review, and release engineering drawings.
• Strong understanding of ANSI Y14.5 GD&T standards.

Mechanical Systems Expertise

Experience designing and integrating aircraft mechanical systems, including:

Hydraulic Systems

• Potable water systems
• Wastewater systems
• Coolant systems

Pneumatic Systems

• Air conditioning systems
• Ventilation systems
• Vacuum waste systems

Safety & Environmental Systems

• Smoke detection systems
• Oxygen systems
• Equipment cooling systems

Manufacturing & Product Development

• Design for Manufacturing (DFM) and Design for Assembly (DFA)
• Material selection and specification
• Assembly methods and fabrication processes
• Cost-conscious engineering and production support
• Fit, Form, and Function evaluation of engineering designs

Additional Requirements

• Strong communication and interpersonal skills.
• Ability to work independently and cross-functionally.
• Exceptional organizational and time management skills.
• Ability to support prototype and development-focused engineering environments.
• Ability to travel as required.
• Flexibility to support occasional work outside standard business hours.

Ideal Background

• Aerospace or aviation engineering experience.
• Aircraft interiors, VIP completions, modifications, or systems integration experience.
• Experience supporting FAA-certified aircraft programs.
• Strong hands-on knowledge of aircraft environmental control, water, waste, oxygen, and ventilation systems.
• Experience supporting engineering through production, testing, and certification phases.