Senior Design Engineer

Title: Senior Design Engineer

Location: Mansfield, MA

Job Description:

Mandatory Skills:

• Bachelor s degree in mechanical engineering or a related field
• 8+ years of hands-on mechanical engineering experience
• Strong proficiency in CAD software: SolidWorks, Autodesk Inventor, Siemens NX
• Experience performing FEA and CFD analysis using ANSYS or equivalent tools
• Experience performing design analyses on aerospace components
• Outstanding communication and technical writing skills
• Ability to work effectively in cross-functional engineering and manufacturing environments
• Outstanding customer interfacing skills

Preferred Qualifications

• Experience designing hardware that interfaces with electronic systems or avionics
• An understanding of engineering outsourcing business practices
• Knowledge of common manufacturing processes
• Exposure to project or program management
• Experience writing or creating standard work, establishing processes, and documenting lessons learned An alignment with company values, including Being Purposeful, Ethics & Integrity, Caring, A Culture of Learning, and Results with Accountability.

Physical Requirements:

• Prolonged periods sitting at a desk and working on a computer
• Ability to traverse and navigate a manufacturing facility
• Must be able to lift up to 15 pounds at times

Primary Responsibilities

• Perform engineering design analyses such as tolerance stacks, hand calculations, etc. to evaluate the fit, form, and function of a part, while balancing manufacturing and cost constraints.
• Create detailed mechanical designs, layouts, and engineering drawings using CAD tools such as SolidWorks, Autodesk Inventor, and Siemens NX
• Perform Finite Element Analysis (FEA) and Computational Fluid Dynamics (CFD) to validate structural integrity, thermal behavior, and performance using ANSYS tools
• Build, test, and analyze prototypes to verify functionality, safety, and reliability
• Collaborate closely with manufacturing and supply chain teams to ensure Design for Manufacturability (DFM) and cost-effective production
• Develop and maintain Bill of Materials (BOMs) in customer PLM, technical documentation, and engineering reports
• Apply and review GD&T per ASME Y14.5 standards to ensure design intent and quality
• Support certification and compliance activities related to FAA, TCCA, and OEM requirements
• Participate in design reviews and provide technical leadership throughout the product lifecycle
• Identify opportunities for continuous improvement to current engineering processes, tools, trainings, etc.
• Update status reports, present project status to customers, and work with client project management to ensure productive and consistent customer communication.
• Understand and adhere to all export control regulations.
• Travel locally onsite to the customer facility several days per week as needed and comply with all customer site requirements.