Mechanical Design Engineer [Propulsion]

Responsibilities

• Own the mechanical design and integration of propulsion components and subsystems (motors, generators, inverters, turbines, structures and cooling systems)
• Drive resolution of real hardware issues discovered during prototype and early production builds
• Create and maintain 3D CAD models and 2D drawings, including GD&T and tolerance stackups
• Perform DFM/DFA trade studies, balancing weight, cost, thermal performance, reliability, and manufacturability
• Work with suppliers and internal teams to assess manufacturing feasibility, refine designs, and rapidly resolve build issues
• Support hands-on prototype assembly, integration, and test, including debugging and root cause analysis
• Conduct engineering analysis using a mix of hand calculations and FEA to inform design decisions
• Implement and refine thermal management strategies (air and/or liquid cooling, heat sinks, TIMs, enclosures, insulation)
• Translate test data and build feedback into actionable design improvements
• Document designs, analyses, and design changes clearly to support team alignment and future production

Requirements

• B.S. or M.S. in Mechanical Engineering, Aerospace Engineering, or a related field
• 4+ years of experience in mechanical design of complex systems (or equivalent demonstrated capability)
• Experience owning the design of a critical assembly or subsystem from concept through build, test, and iteration
• Proficiency in 3D CAD (NX preferred) and creating production-quality drawings with GD&T
• Strong understanding of tolerance stack-ups and real-world fit/integration challenges
• Experience designing for a range of manufacturing processes (machining, sheet metal, additive, etc.)
• Hands-on experience building, testing, and troubleshooting hardware
• Comfortable working on electromechanical systems (motors, power electronics, rotating machinery, batteries, cooling systems, etc.)
• Demonstrated ability to debug issues, perform root cause analysis, and drive corrective actions
• Experience working in fast-paced, iterative hardware development environments
• Strong problem-solving skills, attention to detail, and bias toward action
• Clear communicator who collaborates effectively across multidisciplinary teams

Nice to Have

• Experience with propulsion systems or electromechanical systems
• Familiarity with rotating machinery, vibration, and structural dynamics considerations
• Background in thermal management of high-power systems (liquid cooling, forced air, heat exchangers)
• Experience performing thermal and/or structural analysis (FEA, analytical modeling, or CFD)
• Experience supporting prototype builds and early production environments
• Familiarity with PLM systems (Teamcenter preferred)
• Background in aerospace, automotive (EV/powertrain), robotics, or similar high-performance hardware industries