Senior Design Engineer (Aerospace & Defense Hardware)

Job Description

Job Description

SENIOR DESIGN ENGINEER (AEROSPACE & DEFENSE HARDWARE)

Freeform builds AI-native manufacturing systems that unify software, hardware, and physics to produce industrial-scale parts at the speed of human ideation. By treating manufacturing as a single integrated system, we unlock a new era of innovation where complex hardware is designed, built, and scaled without limits.

Freeform is hiring a Senior Design Engineer focused on aerospace & defense hardware to sit at the intersection of advanced part design and additive manufacturing. This is a deeply technical senior engineering role responsible for rethinking how aerospace and defense hardware is conceived, designed, and produced - not just adapting existing parts for a new process, but fundamentally reimagining what's possible when legacy design constraints no longer apply. You will own complex design challenges end-to-end, working hands-on with some of the most complex hardware in the industry, and serve as a technical authority on where Freeform's platform unlocks performance regimes, architectures, and geometries that were previously impractical or impossible.

The ideal candidate is a highly experienced mechanical or aerospace engineer with deep intuition for part design, a genuine passion for pushing the boundaries of what hardware can do, and a track record of leading technical work on complex hardware programs. They understand aerospace and defense systems at a component and systems level, can independently drive and mentor others on manufacturability, materials, and performance tradeoffs, and are excited by the creative challenge of designing parts from first principles. The core draw of this role is the engineering itself - though this person will also engage directly with some of the most sophisticated frontier companies in the aerospace and defense industries.

Responsibilities:  

• Drive part design and redesign across a broad range of aerospace and defense hardware, including: 
  • Propulsion systems 
  • Heat exchangers and thermal management hardware 
  • Valves and fluid systems 
  • Turbomachinery components 
  • Combustion devices 
  • Lightweight structural components and assemblies 
• Develop and own deep component-level understanding of requirements, performance drivers, and system constraints within aerospace and defense programs 
• Lead first-principles part redesigns, identifying where additive manufacturing enables new geometries, consolidated assemblies, improved performance, or reduced cost and lead time 
• Define and evaluate design concepts with expert command of materials, tolerances, thermal and structural behavior, and production considerations 
• Serve as a senior technical resource - independently resolving advanced questions related to design tradeoffs, process capabilities, qualification pathways, and production scalability, and helping guide less experienced engineers 
• Partner closely with internal engineering and operations teams to drive feasibility, refine concepts, and own execution outcomes 
• Lead technical engagements with customer engineering teams to understand application requirements, present design solutions, and establish deep technical credibility at a senior level 
• Identify, scope, and champion new application spaces where Freeform's technology can deliver step-change improvements over conventional manufacturing 
• Shape Freeform's product, process, and technology roadmap through field-informed technical leadership and strategic input 

Basic Qualifications:  

• Bachelor's degree in mechanical or aerospace engineering 
• 5+ years of experience in a hands-on engineering role within aerospace, defense, or a closely related high-performance industry 
• Demonstrated ability to lead complex hardware programs from concept through qualification and production 
• Experience designing or analyzing propulsion systems, thermal systems, fluid systems, turbomachinery, or high-performance structural components 
• Deep systems-level understanding of complex mechanical hardware and how components function within larger assemblies 

Nice to Have:  

• 10+ years of experience in a hands-on engineering role within aerospace, defense, or a closely related high-performance industry 
• Familiarity with metal 3D printing or design for additive manufacturing (DFAM) concepts 
• Strong intuition for part design, design-for-manufacturing, and how component geometry relates to performance and producibility 
• Experience mentoring engineers and providing technical direction on hardware development programs 
• Experience carrying hardware through development, qualification, and production ramp 
• Ability to clearly communicate complex technical concepts to both engineering and non-engineering stakeholders 
• Strong first-principles reasoning and comfort operating in ambiguous, fast-moving problem spaces 
• Strategic thinker with an instinct for where technology can unlock the most value 
• Team player, positive attitude, growth mindset, integrity, accountability, adaptability, entrepreneurial, driven, results-oriented and ethical 

Location:  

• Based in Hawthorne, our vertically integrated facility brings technology development, R&D, and production together under one roof. We operate at the center of LA's deep tech ecosystem, surrounded by some of the most ambitious hardware innovation happening anywhere in the country. 
• Our fast-paced, cross-functional environment is built on close collaboration, and as such, this role requires full-time onsite presence (five days a week), with very limited exceptions. 

What We Offer:  

• We have an inclusive and diverse culture that values collaboration, learning, and making deliberate data-driven decisions. 
• We offer a unique opportunity to be an early and integral member of a rapidly growing company that is scaling a world-changing technology. 
• Benefits 
  • Significant stock option packages 
  • 100% employer-paid Medical, Dental, and Vision insurance (premium PPO and HMO options) 
  • Life insurance 
  • Traditional and Roth 401(k) 
  • Relocation assistance provided 
  • Paid vacation, sick leave, and company holidays 
  • Generous Paid Parental Leave and extended transition back to work for the birthing parent 
  • Free daily catered lunch and dinner, and fully stocked kitchenette 
  • Casual dress, flexible work hours, and regular catered team building events 
• Compensation   
  • As a growing company, the salary range is intentionally wide as we determine the most appropriate package for each individual taking into consideration years of experience, educational background, and unique skills and abilities as demonstrated throughout the interview process. Our intent is to offer a salary that is commensurate for the company's current stage of development and allows the employee to grow and develop within a role.  
  • In addition to the significant stock option package, the estimated salary range for this role is $150,000-$200,000. The upper end of the range is reserved for individuals who demonstrate exceptional experience, deep domain mastery, and a proven history of high performance and impact. 
• Freeform is an Equal Opportunity Employer that values diversity; employment with Freeform is governed on the basis of merit, competence and qualifications and will not be influenced in any manner by race, color, religion, gender, national origin/ethnicity, veteran status, disability status, age, sexual orientation, gender identity, marital status, mental or physical disability or any other legally protected status.