Senior Mechanical Engineer

Position SummaryWe are seeking a technically rigorous Senior Mechanical Engineer to join a multidisciplinary defense engineering team developing autonomous maritime and airborne systems. This role spans the full engineering lifecycle — from rapid concept prototyping through production-quality design, test execution, and fielding support — in direct support of U.S. Navy and other defense programs.The successful candidate will bring deep technical grounding in core mechanical engineering disciplines (mechanics of materials, fluid dynamics, thermodynamics and heat transfer), hands-on experience with advanced manufacturing equipment and composite fabrication, and practical familiarity with defense acquisition processes and Systems Engineering best practices.Essential Duties and ResponsibilitiesStructural & Mechanical DesignDesign mechanical systems and structures to meet operational requirements with clearly documented and verified safety factors adequate for sustained military useApply mechanics of materials principles — stress, strain, fatigue, fracture mechanics, and failure mode analysis — to all structural designsPerform FEA and analytical hand calculations to validate designs prior to fabrication; iterate rapidly based on resultsProduce engineering drawings, GD&T specifications, and design documentation compliant with defense acquisition standardsRapid Prototyping & ManufacturingExecute rapid design-build-test cycles to quickly evaluate concepts and reduce integration risk before committing to production-quality solutionsOperate and program CNC mills, waterjets, and 5-axis laser systems; manage toolpaths and setup for complex geometry partsDesign, lay up, and cure composite structures using traditional wet lay-up, Resin Transfer Molding (RTM), and Vacuum-Assisted Resin Transfer Molding (VaRTM) processesSpecify fiber architectures, core materials, resin systems, and cure cycles to meet structural, thermal, and weight requirementsSupport DfM studies and tolerance analyses using GD&T and SolidWorks or equivalent CAD toolsFluids, Thermal & Propulsion AnalysisApply fluid dynamics to internal and external flow problems including hydrodynamic loading, drag reduction, and hydraulic system designConduct thermodynamic and heat transfer analyses to ensure thermal margins are maintained across operating environments, including shock, vibration, and submersionSupport design of thermal management systems for electronics, actuators, and propulsion subsystems in maritime and airborne platformsTest & Field SupportPlan and execute System Integration Lab (SIL) and Hardware-in-the-Loop (HIL) test campaigns; develop test procedures, collect and analyze data, and produce test reportsDeploy to field environments in support of Navy, Air Force, and joint military exercises and operational demonstrationsSupport instrumentation setup including strain gauges, accelerometers, load cells, and environmental sensors; calibrate and validate measurement systemsAuthor and review test documentation (TEMP, test plans, test reports) in compliance with DoD 5000 series acquisition standardsSystems EngineeringApply MBSE frameworks to decompose operational requirements into system architectures, interfaces, subsystem specifications, and design behaviorsAuthor and maintain Systems Engineering documentation including SEPs, ICDs, ECPs, CDRLs, and configuration management recordsIdentify and manage technical risk through structured FMEA, reliability analysis, and design review processesLiaise across software, autonomy, electrical, and systems teams to resolve integration conflicts and maintain design coherenceSupport configuration control processes through standard CM tools; manage ECPs and PECPs through design change lifecycleRequired QualificationsCandidates must meet one of the following thresholds:Ph.D. in Mechanical Engineering with 5+ years of relevant professional experienceM.S. in Mechanical Engineering with 7-10 years of relevant professional experienceB.S. in Mechanical Engineering field with 10+ years of relevant professional experienceDemonstrated mastery of mechanics of materials: stress analysis, fatigue, fracture, failure modes, and selection of appropriate safety factors for operational useDemonstrated mastery of fluid dynamics: internal and external flows, hydrodynamic loading, CFD interpretation, and hydraulic system designDemonstrated mastery of thermodynamics and heat transfer: conduction, convection, radiation, thermal management system design, and environmental qualificationDirect hands-on experience with CNC machining, waterjet cutting, additive manufacturing techniques, and 5-axis laser systems — including setup, fixturing, and toolpath programmingDirect experience fabricating composite structures via at least two of: traditional wet lay-up, RTM, and/or VaRTM processesProficiency in 3D CAD (SolidWorks, CATIA, or equivalent) with GD&T drawing productionFamiliarity with FEA tools (ANSYS, NASTRAN, or equivalent) for structural and thermal analysisExperience supporting military or Government testing or exercises in a direct technical roleWorking knowledge of Systems Engineering best practices and documentation in the aerospace or defense sectorActive U.S. Secret clearance (or ability to obtain)Additional Desired QualificationsExperience with autonomous maritime systems (USV, UUV, AUV) or autonomous airborne systems (UAS, cruise missiles)Experience with MBSE tools such as Cameo Systems Modeler or equivalentFamiliarity with PID control system integration and SIL/HIL test environmentsExperience with sonar, radar, EO/IR, ordnance, or other defense sensor payloadsActive TS/SCI clearanceExperience applying ITAR, DoD 5000, MOSA/WOSA, or AS9100/ISO9001 compliance requirementsPublication record or demonstrated subject matter expertise in a relevant technical disciplinePhysical Requirements and Working ConditionsMust be able to walk, stand, and navigate large indoor and outdoor facilities for extended periods of time.Ability to lift, carry, and move materials and equipment weighing up to 25 lbs on a regular basis.Use of personal protective equipment (PPE) may be required in designated areas or when performing specific tasks, in accordance with safety protocols and company policy.May be required to climb ladders, stoop, kneel, or crouch during inspections, maintenance walk-throughs, or emergency response situations.Regular exposure to facility operations including noise, dust, temperature fluctuations, and industrial equipment.Occasional off-hours or weekend work required for emergency facility responses or projects as neededRequires frequent use of a computer and other standard office equipment for documentation, communication, and coordination tasks.Background CheckThis position will require successfully completing a post-offer background check. Qualified candidates with a criminal history will be considered and are not automatically disqualified, consistent with federal and state law.EEO and ITAR/EAR Work Authorization DisclosureRed Cat Holdings provides equal employment opportunities (EEO) to all employees and applicants for employment and prohibits discrimination and harassment of any type without regard to race, color, religion, age, sex, national origin, disability status, genetics, protected veteran status, sexual orientation, gender identity or expression, or any other characteristic protected by federal, state or local laws. This position requires direct or indirect access to hardware, software, technology or technical data controlled under the International Traffic in Arms Regulations (ITAR) and the Export Administration Regulations (EAR). Successful candidates for positions subject to ITAR/EAR restrictions must provide proof of U.S. Citizenship or Permanent Residence and must not require sponsorship for export-restricted work authorization.E-VerifyThe company participates E-Verify ensure eligibility for employment and compliance with Right to Work rules.Compensation: Base pay, plus generous annual equity package and potential bonuses. #J-18808-Ljbffr