Job brief
We are looking for a highly skilled Aerospace Mechanical Engineer to join our propulsion systems team and lead the design of critical flight hardware for next-generation aircraft. In this role, you will own the end-to-end development cycle of mechanical assemblies, from initial CAD modeling and thermal analysis to prototype flight testing. You will collaborate with cross-disciplinary teams to integrate mechanical systems into broader vehicle architectures while adhering to strict safety and regulatory frameworks. If you are passionate about pushing the limits of aerospace innovation and thrive on solving complex multi-physics challenges, we want you on our team.
Key highlights
- Design and optimize high-tolerance aerospace components using CATIA V5 or Siemens NX to meet stringent weight and structural performance requirements.
- Perform detailed finite element analysis (FEA) to validate the durability of airframe and engine assemblies under high-thermal and high-vibration flight loads.
- Coordinate with supply chain and manufacturing teams to ensure the manufacturability of precision-machined parts and composite structures via DFM principles.
- Lead root cause analysis investigations for flight-test anomalies, documenting findings and implementing robust corrective actions per aerospace engineering standards.
What is a Aerospace Mechanical Engineer?
An Aerospace Mechanical Engineer is a specialized professional who applies advanced principles of thermodynamics, aerodynamics, and structural mechanics to design and develop flight-capable hardware. Working at the intersection of material science and mechanical systems, an Aerospace Mechanical Engineer utilizes high-fidelity tools such as ANSYS, CATIA, and Nastran to simulate extreme operational environments. By bridging the gap between theoretical flight physics and practical manufacturing, these engineers ensure that every component meets rigorous FAA or military airworthiness standards while pushing the boundaries of aviation and space exploration technology.
What does a Aerospace Mechanical Engineer do?
On a typical day, an Aerospace Mechanical Engineer performs structural integrity analysis on airframe components and runs computational fluid dynamics (CFD) simulations to optimize lift-to-drag ratios. They spend significant time documenting engineering change orders (ECOs), reviewing complex BOMs, and verifying that design specifications comply with AS9100 quality management systems. Collaboration is constant, as they work alongside propulsion teams, avionics technicians, and manufacturing engineers to conduct vibration testing or troubleshoot hydraulic flight control system failures to maintain mission readiness.
Key responsibilities
- Design and optimize high-tolerance aerospace components using CATIA V5 or Siemens NX to meet stringent weight and structural performance requirements.
- Perform detailed finite element analysis (FEA) to validate the durability of airframe and engine assemblies under high-thermal and high-vibration flight loads.
- Lead root cause analysis investigations for flight-test anomalies, documenting findings and implementing robust corrective actions per aerospace engineering standards.
- Coordinate with supply chain and manufacturing teams to ensure the manufacturability of precision-machined parts and composite structures via DFM principles.
- Conduct comprehensive performance validation testing for mechanical actuators, landing gear systems, and pressurized cabin environmental control components.
- Prepare and maintain detailed engineering documentation, including stress reports, material specifications, and technical data packages for certification audits.
- Integrate mechanical subsystems into the main vehicle assembly while ensuring compatibility with electronic, hydraulic, and software-driven interface requirements.
- Monitor real-time telemetry data during ground and flight testing phases to evaluate mechanical system health and identify potential failure points.
Requirements and skills
- Bachelor’s degree or higher in Aerospace Engineering, Mechanical Engineering, or a related technical field from an ABET-accredited institution.
- Minimum of 3+ years of professional experience in mechanical design within the aerospace, defense, or space sectors.
- Advanced proficiency in 3D CAD modeling software such as CATIA, SolidWorks, or Creo, with a focus on parametric assembly design.
- Deep understanding of geometric dimensioning and tolerancing (GDMT) per ASME Y14.5 standards for complex aerospace hardware.
- Demonstrated expertise in simulation tools including ANSYS Mechanical, Abaqus, or Star-CCM+ for multi-physics engineering analysis.
- Familiarity with aerospace-specific industry regulations and standards, including AS9100, DO-178C, or FAA Part 23/25 certification requirements.
- Ability to communicate complex technical findings to non-engineering stakeholders, project managers, and regulatory officials clearly and concisely.
- Active professional certifications such as an EIT or PE license are highly preferred for candidates pursuing senior engineering roles.
FAQs
What does an Aerospace Mechanical Engineer do?
An Aerospace Mechanical Engineer focuses on the mechanical aspects of flight vehicles, such as airframes, propulsion systems, and landing gear. Their work involves designing these parts, testing them for structural resilience under extreme pressure, and ensuring they comply with strict aerospace safety regulations. They play a critical role in converting complex aerodynamic requirements into physical, flight-ready hardware.
What skills are required for an Aerospace Mechanical Engineer?
Key skills include proficiency in CAD software (like CATIA or Creo), a deep understanding of FEA/CFD simulation, and mastery of material science and mechanical dynamics. Additionally, they must be well-versed in industry-specific standards like AS9100 and have the ability to translate technical specifications into manufacturable parts. Strong analytical problem-solving is essential for root cause analysis during flight-test failures.
Who does an Aerospace Mechanical Engineer work with?
They work in a highly collaborative environment alongside propulsion engineers, avionics and electrical systems engineers, and material scientists. They also interact heavily with manufacturing teams to oversee prototyping, quality assurance inspectors to verify compliance, and project managers to ensure development timelines align with flight-test schedules.
How do you become an Aerospace Mechanical Engineer?
Becoming an Aerospace Mechanical Engineer typically requires a Bachelor's degree in Aerospace or Mechanical Engineering, often supplemented by internships in the aerospace or defense industry. Gaining hands-on experience with engineering simulation software and understanding regulatory frameworks is vital. Many successful engineers further their careers by obtaining a Professional Engineer (PE) license or a Master's degree in a specialized concentration like orbital mechanics or composite structures.