Senior Aero-Mechanical Engineer
$122,000–$153,000 year
On-siteHuntsville, Alabama, United States
Job Summary
Lead the design, modeling, and analysis of major mechanical and structural subsystems for uncrewed aerial systems, performing tolerance and structural analysis while overseeing design documentation and configuration management. Coordinate design integration across mechanical, electrical, and software disciplines, guide prototype builds, and execute test plans to validate structural integrity and system performance. Participate in design reviews, mentor junior engineers, and contribute to continuous improvement initiatives in design standards and documentation processes. Support production readiness and quality verification for new and existing products.
Required Qualifications
- Bachelor's degree in Mechanical Engineering, Aerospace Engineering, or a related field
- 4–7 years of relevant experience in mechanical or aerospace engineering
- demonstrated ownership of major subsystems or assemblies
- Proven experience developing products for aerospace, defense, or similarly regulated environments
- Experience supporting prototype, production, and test activities in a hands-on capacity
- Advanced proficiency with CAD modeling and drafting
- SolidWorks
- Deep understanding of GD&T, mechanical drawing standards, and documentation control
- Working knowledge of materials, composites, machined parts, and structural integration
- Experience performing FEA and interpreting results for design optimization
- Familiarity with PDM/PLM systems
- SolidWorks PDM
- Windchill
- Strong technical leadership and decision-making skills
- Excellent communication and collaboration across multi-disciplinary teams
- Analytical mindset with strong problem-solving and root-cause analysis capabilities
- Organized and detail-oriented with experience managing multiple design tasks simultaneously
- Ability to mentor others and uphold engineering rigor and design quality
- Ability to lift up to 30 pounds
Desired Qualifications
- Master's degree in Mechanical or Aerospace Engineering
- 6–8 years of experience designing mechanical systems for UAS or defense applications
- Experience leading subsystem integration efforts and participating in flight or environmental testing
- Experience with advanced analysis tools (FEA, CFD, or fatigue analysis)
- Familiarity with composite layup design, bonded structures, or lightweight mechanisms
- Experience developing and reviewing engineering standards or process documentation
- Familiarity with systems engineering practices and requirements traceability
- Strong leadership presence with the ability to influence technical direction
- Ability to synthesize feedback from multiple stakeholders into actionable design decisions
- Continuous improvement mindset, with a focus on efficiency and repeatable design excellence
- Comfort operating in fast-paced environments with evolving program requirements
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