Senior Mechanical Engineer

Location: Middlesex County, NJ

Industry: Aerospace Manufacturing

Position Overview

An aerospace manufacturer is seeking a Senior Mechanical Engineer with strong electromechanical packaging experience to lead the mechanical design and development of products for demanding aerospace applications.

This role will work closely with electrical engineering, manufacturing, quality, and suppliers to develop reliable, manufacturable designs from concept through qualification and production. The ideal candidate has experience packaging electronic assemblies and addressing thermal, structural, vibration, and environmental requirements.

Key Responsibilities

• Design and develop mechanical enclosures, housings, chassis, mounting structures, and hardware for electromechanical products.
• Integrate circuit boards, connectors, wiring, and electrical components into mechanical assemblies while addressing space constraints, accessibility, and serviceability.
• Collaborate with electrical engineers to establish component placement, mechanical interfaces, and packaging requirements.
• Develop thermal management solutions, including heat sinks, conduction paths, and cooling arrangements.
• Perform or coordinate structural, thermal, and vibration analyses to verify design performance.
• Create and release 3D models, engineering drawings, bills of materials, and supporting documentation.
• Apply GD&T, tolerance analysis, and design for manufacturing and assembly principles.
• Select materials, finishes, fastening methods, and manufacturing processes appropriate for aerospace operating environments.
• Support prototype builds, qualification testing, failure investigations, and corrective actions.
• Work with suppliers and manufacturing teams to resolve technical issues, improve producibility, and reduce costs.
• Lead design reviews and provide technical guidance to other engineers.
• Manage engineering changes and maintain accurate configuration-controlled documentation.

Required Qualifications

• Bachelor’s degree in Mechanical Engineering or a related engineering discipline.
• Five or more years of mechanical design experience, including hands-on electromechanical packaging.
• Experience designing enclosures and assemblies for electronics or electrical equipment.
• Proficiency with 3D CAD software, such as SolidWorks, Creo, or an equivalent platform.
• Strong understanding of GD&T, tolerance stackups, engineering drawings, and mechanical interfaces.
• Experience with machined parts, sheet metal, and mechanical assembly processes.
• Working knowledge of thermal management, structural integrity, and vibration considerations.
• Experience supporting products from design through manufacturing and testing.
• Strong problem-solving, communication, and cross-functional collaboration skills.

Preferred Qualifications

• Experience in aerospace, defense, or another highly regulated manufacturing environment.
• Experience packaging power electronics, power conversion equipment, avionics, or similar electronic systems.
• Familiarity with environmental qualification requirements, such as RTCA DO-160 or MIL-STD-810.
• Experience with finite element analysis and thermal simulation tools.
• Familiarity with EMI/EMC shielding, grounding, sealing, and connector integration.
• Experience working within an AS9100 quality management system.
• Experience leading technical projects and mentoring engineers.