Senior Design Engineer

Senior Design Engineer

Employment Type: Full-Time

Salary Range: $90,000 – $125,000 (commensurate with experience)

Relocation assistance provided.

Position Summary

We are seeking a highly skilled and experienced Senior Design Engineer to lead the development of advanced mechanical components and brazed assemblies for aerospace and defense applications. This role is responsible for concept development, detailed design, DFM/DFA optimization, and full lifecycle support, with a strong emphasis on engineered brazed joints and precision-machined components.

Key Responsibilities

• Lead mechanical design of machined parts and brazed assemblies using 3D CAD tools (Creo preferred)
• Develop robust, lightweight, and thermally/mechanically efficient designs aligned with aerospace and defense standards
• Define and optimize joint geometry and material compatibility for high‑temperature vacuum brazing applications
• Collaborate with manufacturing, quality, and materials engineering to ensure manufacturability and cost‑effectiveness
• Create and maintain comprehensive engineering documentation, including drawings, BOMs, specifications, and test plans
• Perform FEA and tolerance stack‑up analysis to validate performance under thermal, structural, and vibrational loads
• Participate in design reviews, root cause investigations, and continuous improvement initiatives
• Mentor junior engineers and provide technical leadership across projects
• Interface with customers and suppliers to clarify design intent and technical requirements
• Ensure compliance with industry regulations, including AS9100 and ITAR

Required Qualifications

• Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, or a related field
• Minimum 7 years of mechanical design experience in aerospace and/or defense industries
• Proven expertise in precision machining, tight tolerance design, and high‑temperature brazed joints
• Strong understanding of GD&T, tolerance analysis, and CNC machining processes (milling, turning, grinding)
• Proficiency in 3D CAD (Creo preferred) and FEA tools
• Familiarity with AS9100, ITAR, and aerospace customer specifications
• Excellent communication skills and ability to work cross‑functionally

Preferred Qualifications

• Hands‑on experience with vacuum or dip brazing process design (required)
• Exposure to heat transfer and thermal stress analysis for high‑temperature applications
• Background in defense contracting or experience working with DoD primes
• Knowledge of manufacturing process validation and First Article Inspection (FAI)

Seniority level: Mid‑Senior level

Job function: Aviation and Aerospace Component Manufacturing