Senior Staff Engineer, Mechanical Design (R4486)

Responsibilities

• Design complex electro-mechanical mechanisms for autonomous aircraft
• Own the full design process: concept, CAD, tolerance analysis, material selection, and drawing release
• Perform structural and kinematic calculations and preliminary FEA
• Prototype, test, and iterate mechanism designs for functionality and reliability
• Collaborate with electrical, avionics, flight controls, and propulsion teams
• Mentor junior engineers and promote engineering excellence
• Support pre-production builds, prototype integration, and ground/flight testing

Required Qualifications

• B.S. in Mechanical/Aerospace Engineering
• 8+ years in mechanical or mechanism design
• Strong CAD skills (NX preferred)
• Kinematic analysis and optimization
• Structural analysis utilizing hand calculations and finite element methods
• FEA analysis: Modal, non-linear and linear, buckling, fatigue
• GD&T and tolerance stack-ups for mechanical systems
• Materials selection inclusive of alloys, heat treatments, allowables, and finishes
• Ability to work independently and lead in fast-paced, cross-functional teams

Preferred Qualifications

• Experience with UAVs, aircraft, or robotic systems
• Familiarity with electro-mechanical actuators
• Proficiency in FMEA, DOE, and root cause analysis
• Hands-on machine shop or mechanic experience (professional or hobby)
• RTCA DO-160, structural, or actuated mechanism testing experience
• Ability to thrive in startup, R&D, or defense innovation environments