Principal Mechanical Engineer - Flight

LEAP Principal Mechanical Engineer - Flight Broomfield, CO·Full time Company website

As our Principal Mechanical Engineer - Flight, you will lead the design and development of detailed 3D CAD models and fabrication drawings that bring our rocket vehicles flight hardware to reality. From internal frames and load-bearing mounts to fully integrated flight assemblies, you will ensure that every mechanical system is efficiently designed for minimal mass, ease of integration, manufacturability, and robust flight performance.

About LEAP

LEAP is transforming space logistics with rapid-response, mass producible launch solutions designed to eliminate bottlenecks in space access. Leveraging proprietary propulsion technology and modern manufacturing techniques, LEAP delivers scalable and cost-effective, launch solutions for national security, commercial payload deployment, and global point-to-point logistics applications.

Description

Own Core Responsibilities

• Own complex major flight assemblies to complete stages end-to-end.
• Serve as a technical leader within the mechanical team and mentor junior engineers.
• Work closely with structures, propulsion, avionics, and manufacturing to drive successful flight outcomes.
• Lead a technical team of 4–10 people to deliver consistent mechanical and structural design results.
• Manage and deliver all levels of design reports, designs, documentation, analyses, etc.

Impacts and Outcomes

• Own and Lead Flight Hardware Design: Develop and own 3D CAD models of primary flight hardware (Liquid Rocket Vehicle Stages, Payload Fairings, Complete Fluid Systems, etc.), taking assemblies from concept through release.
• Drive Structural & Mass Optimization: Perform hand calculations and FEA to validate designs, define load paths, and ensure compliance with stress and mass requirements
• Technical Leadership: Guide design standards, mentor junior engineers and designers, and contribute to architectural decisions impacting overall vehicle configuration.
• System-Level Collaboration: Work cross-functionally with propulsion, avionics, GNC, and manufacturing to define and ensure interface control (bolting patterns, harness pass-throughs, thermal interfaces, tolerance stacks, etc.) meets system-level requirements.
• Manufacturing Integration: Lead design reviews with internal teams and vendors. Ensure hardware is DFM/DFA compliant and proactively resolve producibility risks.
• Produce Flight-Ready Documentation: Deliver BOMs and detailed component and assembly drawings that follow GD&T standards and aerospace best practices, ensuring unambiguous build and inspection criteria.
• Own Configuration & CAD Integrity: Maintain part libraries, revision histories, interface control documentation, and BOM accuracy within PLM systems, ensuring the engineering team operates from a single source of truth.

Required Skills

• Relevant 12+ years of experience in mechanical design for high-performance systems, preferably in the aerospace industry
• Demonstrated ownership of major assemblies from concept through flight or production
• Demonstrated leadership of small to medium size technical teams
• Proficiency in 3D CAD software (preferably NX) and strong command of GD&T principles
• Experience performing FEA and hand calculations to validate flight-critical hardware
• Strong understanding of lightweight aerospace design best practices (material selection, structural efficiency, geometric optimization)
• Proven experience applying DFM and DFA methodologies, with practical knowledge of fabrication techniques including welding, machining, and additive processes
• Familiarity with PLM systems (preferably Teamcenter) and configuration management for large assembly designs
• Organized, detail-oriented approach to CAD data management, BOM creation, revision control, and collaborative environments

Bonus Points

• Experience in high-growth, startup, or technically complex environments
• Additional skills or domain knowledge relevant to the role

Compensation

Salary Range: $175,000 – $250,000

The estimated salary range for this role reflects various compensation factors. The final offer depends on factors such as work experience, education, training, key skills, and business needs.

In addition, LEAP provides a comprehensive benefits package for full-time employees, which includes:

• Equity Program: Equity plan participation is available to all employees following an initial 90-day employment period and is performance-based. Equity allocations are determined on a case-by-case basis and are not guaranteed. Managers may make recommendations based on individual and team performance. All equity grants are subject to executive review and approval in accordance with the Company’s equity plan.
• Retirement Planning: Save for the future with a 401(k) plan that includes competitive company matching.
• Growth Opportunities: Take advantage of a professional development stipend to advance your skills and expertise.
• Flexible Time Off: Enjoy PTO as needed and holiday breaks to help you balance work and life, including two week long company winter breaks and paid leave to support a family member, bond with a new child, or manage your own health needs
• Remote Work Flexibility: Our team operates on a hybrid model. We expect you to work with your team for specific details on work location.
• Health Benefits: LEAP provides comprehensive medical, dental, and vision coverage at minimal to no cost for employees. Coverage for dependents and HSA are also available.
• Insurance Coverage: We cover basic life and long-term disability insurance, with options to add extra coverage to ensure peace of mind for you and your family.

LEAP is proud to be an equal-opportunity employer committed to building a diverse and inclusive workplace in Colorado. Our team brings together exceptionally talented and diverse individuals who are pushing the boundaries of space access and logistics. We welcome all qualified applicants and provide equal consideration for employment regardless of race, color, religion, sex, gender identity, sexual orientation, national origin, disability, Veteran status, age, or any other protected characteristic under federal, state, or local law. This includes individuals with a criminal history, in compliance with applicable regulations. We actively encourage applications from minorities, women, Veterans, and people with disabilities. At LEAP, we strive to create a supportive and welcoming environment throughout the hiring process. If you’re excited about making a real-world impact in space technology, we want to hear from you!