Principal Mechanical Systems Designer

Mechanical Design Engineer Position

At our organization, we strive to create a positive impact by designing and building innovative solutions that make the world a better place.

We are seeking a Senior Mechanical Design Engineer to join our dynamic team. The ideal candidate will be responsible for the mechanical design and development of Hybrid UAV systems and subsystems, emphasizing design excellence, manufacturability, integration readiness, and cross-functional collaboration.

The Senior Mechanical Design Engineer will lead the mechanical design of Hybrid UAV subsystems and payload interfaces using advanced parametric CAD tools. They will develop and maintain complex CAD trees, system layouts, and 3D model integrity across revisions. Additionally, they will drive modular and scalable design practices in line with product architecture.

The ideal candidate should bring deep experience in CAD design, tooling & assembly definition (TAD), PLM integration, material-process compatibility, and be capable of taking end-to-end mechanical ownership from design to delivery.

1. CAD-Based Mechanical Design & Ownership:

• Lead the mechanical design of Hybrid UAV subsystems and payload interfaces using advanced parametric CAD tools.
• Develop and maintain complex CAD trees, system layouts, and 3D model integrity across revisions.
• Drive modular and scalable design practices in line with product architecture.

TAD (Tooling & Assembly Definition):

• Must be proficient in TAD principles with hands-on experience in tooling and assembly strategies.
• Prepare assembly BOMs, jigs and fixture interfaces, and support design-to-assembly planning.
• Contribute to design improvements based on ease of assembly, maintainability, and ergonomics.

PLM Integration:

• Experienced in Product Lifecycle Management (PLM) systems for version control, workflows, and digital thread management.
• Familiarity with Windchill PLM or equivalent for part structures, release cycles, and change management.

Structural Design & Collaboration:

• Sound understanding of structural analysis fundamentals (loads, boundary conditions, safety factors, fastener design, etc.).
• Ability to interpret FEA results, collaborate with analysis teams, and optimize design based on structural feedback.

Material Engineering & Manufacturability:

• Strong knowledge of materials (metals, polymers, composites) with a clear understanding of process-specific constraints.
• Evaluate designs for manufacturability, cost efficiency, and reliability using DFM, DFX, and material selection tools.

Additive Manufacturing & 3D Printing:

• Well-versed in 3D printing techniques (FDM, SLA, SLS, MJF, DMLS, etc.).
• Ability to select suitable printer types, grain structures, material properties, and post-processing requirements based on the use-case.

Cross-Functional Collaboration:

• Work closely with systems engineering, integration, sourcing, testing, and manufacturing teams.
• Take ownership of the design deliverables, resolve cross-domain design issues, and ensure on-time maturity of the mechanical stack.
• Support V&V (Validation & Verification) activities and ensure that mechanical designs are compliant with technical specs and regulatory needs.

Root Cause Analysis:

• Should be capable to understand physical behavior, correlate with design definition and derive root causes in collaboration with CFT.

The ideal candidate should have a bachelor's or master's degree in mechanical engineering, aerospace engineering, or a related discipline, with at least 8 years of experience in mechanical product design, preferably in aerospace, UAVs, or robotics.

The candidate should be proficient in 3D CAD modeling (preferably Creo), TAD, and GD&T, with experience in PLM/PDM platforms, ideally Windchill. They should also have exposure to FEA results interpretation and collaborative optimization with analysts, as well as knowledge of DFX, DFM, and high-performance material-process pairing.

Hands-on experience with 3D printing tools and decision-making for rapid prototyping vs. end-use applications is also desirable. Strong documentation and presentation skills are essential for this role.

The desired behavioral values for this position include commitment to common purpose and goals, respect for colleagues, displaying integrity and ethics, taking initiative and ownership with accountabilities, being passionate about making a difference, and maintaining and managing interpersonal harmonious relationships.

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