Aerospace Mechanical Engineer job description

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.

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.

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