Senior Mechanical Design Engineer [Propulsion]
Design and mature mechanical and thermal systems for high-power hybrid-electric propulsion, owning critical hardware from concept through production. The role requires 5+ years of complex mechanical design experience, rotating-machinery expertise, CAD/GD&T proficiency, and hands-on hardware development.
About the job
Responsibilities
- Lead design and analysis of rotating machinery subsystems, including turbines, motors, and generators, addressing vibration, dynamic balancing, bearings, and seals.
- Resolve hardware issues identified during prototype and early production builds.
- Mentor junior and mid-level engineers and provide technical guidance.
- Contribute to propulsion-team planning, technical strategy, design reviews, and technical standards.
- Create and maintain 3D CAD models and 2D production drawings with GD&T and tolerance stack-ups.
- Perform DFM/DFA trade studies balancing weight, cost, thermal performance, reliability, and manufacturability.
- Work with suppliers and internal teams to assess manufacturing feasibility and resolve build issues.
- Support prototype assembly, integration, testing, debugging, and root-cause analysis.
- Conduct hand calculations and FEA to inform design decisions.
- Develop thermal-management strategies involving air or liquid cooling, heat sinks, thermal interface materials, enclosures, and insulation.
- Translate test data and build feedback into design improvements.
- Document designs, analyses, and design changes.
Requirements
- Bachelor's or master's degree in Mechanical Engineering, Aerospace Engineering, or a related field.
- 5+ years of experience in mechanical design of complex systems.
- Experience with high-speed rotating machinery, including vibration, critical speed, dynamic balancing, bearings, and seals.
- Ownership of a critical assembly or subsystem from concept through build, test, and production.
- Proficiency in 3D CAD; NX preferred.
- Ability to create production-quality drawings with GD&T and perform tolerance stack-ups.
- Experience designing for machining, sheet metal, additive manufacturing, and other processes.
- Hands-on experience building, testing, and troubleshooting hardware.
- Experience with electromechanical systems such as motors, power electronics, rotating machinery, batteries, and cooling systems.
- Ability to debug issues, perform root-cause analysis, and drive corrective actions.
- Experience in fast-paced, iterative hardware-development environments.
- Strong communication and cross-functional collaboration skills.
- Technical leadership experience, such as leading design reviews, mentoring engineers, or setting technical standards.
Nice-to-Haves
- Propulsion or electromechanical-systems experience.
- Thermal management of high-power systems, including liquid cooling, forced air, and heat exchangers.
- Rotor dynamics or vibration-analysis tools, including modal and critical-speed analysis.
- Thermal or structural analysis using FEA, analytical modeling, or CFD.
- Prototype-build and early-production experience.
- Familiarity with PLM systems, especially Teamcenter.
- Aerospace, automotive/EV powertrain, robotics, or similar high-performance hardware experience.
Skills
Mechanical Design, Rotating Machinery, Nx, CAD, GD&T, Tolerance Stack-Ups, Dfm/Dfa, FEA, Thermal Management, Rotor Dynamics, Vibration Analysis, Cfd, Root Cause Analysis, Teamcenter, Power Electronics
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