Senior Mechanical Design Engineer / Leader - Aircraft


Boulder, CO

Industry: Aerospace & Defense


11 - 15 years

Posted 7 days ago

  by    Rocky Mansfield

The senior mechanical design engineer will provide direction for a team of mechanical and manufacturing engineers to design, build, and test the structure and mechanical systems of a prototype experimental aircraft in a fast-paced research and development environment. The work will span preliminary design, critical design, system design, manufacturing and assembly support, and flight test. Typically, this work includes but is not limited to structural components, landing gear, flight controls, hydraulic or pneumatic systems, pressurized systems, metal fittings, or similar items and their integration into the overall vehicle.  The senior engineer will accomplish a wide variety of tasks as an individual contributor in addition to leading the design team.Duties and responsibilities may include, but are not limited to, the leading of and participation in these tasks:

  • design the primary and secondary load paths for the vehicle
  • conceptual design, structural layout, sizing, and detail design
  • create 3d/2d definition of parts, assemblies and installations
  • support of fabrication and assembly definition
  • stress analysis using classical and finite element methods
  • establish manufacturing tolerances for production of structural and mechanical components
  • review of manufacturing plans and procedures to ensure compliance with design requirements
  • creation of structural test plans to verify manufacturing processes meet design intent and requirements.
  • hands-on manufacturing and assembly support
  • supporting ground and flight test planning, test execution, and aircraft modifications
  • working on multiple projects at the same time


  • foundation knowledge of aircraft load paths and structural sizing
  • a strong understanding of the theory and practical application of mechanical systems, structure, and performance
  • extensive experience in catia v5 or solidworks
  • an understanding of the basics of composite construction and assembly
  • rapid prototyping experience including 3d printing
  • ability to work in multiple engineering disciplines on an aggressive schedule
  • a minimum of ten years of directly related work experience
  • bachelor of science in a relevant engineering discipline from a top tier engineering institution
  • strong problem solving, organizational, and communication skills
  • strong team player


  • aircraft homebuilding experience or other hands-on design or build experience
  • Radio Control (RC) aircraft or rotorcraft design, build, and flight test experience
  • pilot's license
  • additional degrees or additional relevant work experience

Essential job functions:

  • occasionally required to stand, walk and sit for prolonged periods of time
  • manual dexterity and coordination are required (e.g., to operate computer keyboard)