Senior Mechanical Design Engineer

Senior Mechanical Design EngineerThe Senior Mechanical Design Engineer plays a key role in the design, procurement, fabrication, assembly, integration, start-up, and commissioning of very large-scale automated aerospace assembly systems. This role leads the concept development and detailed design of conventional and automated tooling systems, customized machine tools, and automation equipment for aerospace and other precision manufacturing industries. The engineer participates across the full project lifecycle, from initial concept and stress analysis through commissioning and customer delivery, working closely with multidisciplinary teams to deliver high-performance, production-ready solutions.ResponsibilitiesDesign tools and automation equipment for aircraft and other precision manufacturing industries, including aerospace tooling, jigs, fixtures, and industrial equipment.Lead the concept, development, and detailed design of conventional and automated tooling systems and customized machine tools for aerospace assembly systems and automation.Execute project goals related to the mechanical design engineering department, ensuring designs meet technical, schedule, and quality objectives.Provide engineering support for new product introduction to manufacturing, including production support and coordination with manufacturing and machine shop personnel.Create and revise 3D designs and 2D drawings in accordance with internal and customer requirements, using CAD tools such as CATIA V5, NX, or equivalent software.Self-check and review all designs and drawings prior to final release, ensuring completeness, accuracy, and compliance with standards and requirements.Follow established design procedures, complete required forms, and close all actions associated with internal and customer design processes and reviews.Apply engineering skills in drawings, design, and technical publications, and develop capabilities in advanced analysis, concepting, and stress analysis with appropriate support.Develop and refine technologies related to machine design and integration, jigs and tools, platforms, and operations, while building knowledge in controls.Work autonomously in software tools such as CATIA and GURU for 3D CAD design, modeling, and documentation.Build personal and leadership capabilities in areas such as leading small teams, customer interface, process-based thinking, requirements management, and scheduling and estimation.Field telephone calls and respond to inquiries from build suppliers and shop personnel regarding mechanical design engineering problems and related issues.Ensure all design changes, design change notices (DCNs), and as-built information are properly incorporated into drawings and documentation.Select, record, file, and maintain all component information for concepts and designs, ensuring traceability and configuration control.Perform component and material sizing for designs and request or provide input to cognizant stress analysis engineers as needed.Perform hand calculations and stress analysis, and solicit review and checks from cognizant engineers to validate design integrity.Use and interpret GD&T, schematics, and engineering documentation to ensure designs are manufacturable, functional, and compliant with specifications.Coordinate closely with electrical and software groups, attend controls reviews, and provide mechanical design input as required.Provide leadership to establish and meet design schedule goals, including planning tasks, monitoring progress, and adjusting priorities as needed.Perform peer checks of designs and drawings as required, providing feedback and ensuring adherence to standards and best practices.Understand and follow safety and environmental regulations and identify safety and environmental concerns within designs and processes.Adhere to the Quality System and participate in continuous improvement initiatives related to design processes, tools, and documentation.Support design reviews, customer interface meetings, and supplier coordination activities to ensure alignment on requirements, schedules, and deliverables.Contribute to the full project lifecycle, from concept and design through commissioning and customer delivery, ensuring a smooth transition into production.Perform other engineering duties as assigned to support program, department, and organizational objectives.Essential SkillsBachelor of Science in Mechanical Engineering, a related discipline, or an equivalent combination of education and experience.Five or more years of related experience in one or more of the following: heavy machine design, structural design, aerospace tooling, assembly systems, or automation.Proficiency in designing tools, fixtures, and automation equipment for aerospace and precision manufacturing applications.Strong background in structural design engineering, including component and material sizing and stress considerations.Experience with aerospace tooling and automated manufacturing systems, including assembly tooling and automation equipment design.Proficiency with 3D CAD design using CATIA V5, NX, or equivalent CAD software such as SolidWorks or Pro/Engineer.Ability to create and revise 3D models and 2D drawings that meet internal and customer requirements and standards.Experience with Finite Element Analysis (FEA) software; ANSYS or Femap is preferred.Ability to perform hand calculations and basic stress analysis and to collaborate with dedicated stress analysis engineers.Ability to read and understand drawings and schematics, including electronics, mechanics, hydraulics, and pneumatics.Knowledge of CAD, GD&T, and design for manufacturability (DFM) principles applied to precision technical plans, blueprints, drawings, and models.Knowledge of the practical application of engineering science and technology in mechanical and automation systems.Knowledge of engineering and programming concepts, including electronics, mechanics, hydraulics, pneumatics, and computer programming.Experience supporting new product introduction, production support, and manufacturing environments.Experience with engineering documentation, including design reviews, design presentations, and configuration control of drawings and models.Ability to provide independent checks and feedback on engineering deliverables such as 3D models and 2D drawings.Demonstrated ability to use process-based thinking, manage requirements, and contribute to scheduling and estimation.High level of initiative, effort, and commitment to completing assignments in a timely manner.Ability to work as a self-starter, operate independently, and exercise sound judgment in the absence of explicit direction.Eligibility and ability to obtain and maintain a Secret security clearance, if required by specific projects.Additional Skills & QualificationsManufacturing and machine shop background or relevant hands-on experience in fabrication and assembly environments.Familiarity with a variety of fabrication concepts, practices, and procedures related to tooling, fixtures, and industrial equipment.Experience with aerospace manufacturing and assembly systems, including large-scale automation for aircraft production.Experience with automation equipment design and integration, including coordination with controls, electrical, and software teams.Exposure to jigs, tools, platforms, and operations used in aerospace and precision manufacturing.Experience with design techniques, tools, and principles used in production of precision technical plans and models.Experience with production support, supplier coordination, and resolving mechanical design issues on the shop floor.Experience participating in or leading design reviews and providing customer interface support.Ability to learn and apply new concepts, tools, and technologies quickly and effectively.Motivation to work in a fast-paced organization with evolving project requirements and timelines.Strong communication skills to interact with multidisciplinary teams, suppliers, and customers.Interest in developing leadership capabilities, including mentoring, schedule management, and influencing project outcomes.Desire to work on high-profile aerospace programs and large-scale automation systems with visible impact.Comfort working in collaborative engineering environments where individuals have significant visibility and influence over project outcomes.Work EnvironmentThe role is based in an indoor, office environment that is temperature controlled and designed for engineering work. The engineer spends prolonged periods sitting at a desk and working on a computer, using 3D CAD tools such as CATIA V5, NX, or equivalent software, as well as FEA tools like ANSYS or Femap. The work involves light physical demands, including moving objects up to 20 pounds and frequent use of fingers for typing, mouse use, and detailed computer work. No adverse environmental conditions are expected in the normal course of work. The position follows a standard work schedule, with overtime occasionally required to meet project deadlines, support required travel, or address emergent conditions. Travel may be required up to approximately 20% of the time to support on-site integration, commissioning, supplier visits, or customer meetings. Engineers work alongside experienced tooling and automation engineers in collaborative engineering groups that are large enough to support teamwork yet small