Principal Design Engineer - Engine & Propulsion Systems

Job Summary: Reporting to the Director of Engineering, the Principal Design Engineer is a senior technical leader responsible for the conceptualization, design, analysis, validation, and production readiness of advanced engine and engine system architectures. This role drives engineering excellence from initial specification development through certification and production support, with a strong emphasis on performance, durability, manufacturability, and cost optimization. The ideal candidate brings deep engine design expertise, systems-level thinking, and a passion for high-performance propulsion, preferably within or associated with aviation and/or high-performance applications.

Essential Duties & Responsibilities: An individual in this position must be able to successfully perform the duties and responsibilities listed below. Reasonable accommodation may be made to enable individuals with disabilities to perform essential functions. Additional duties may be assigned.
Engine & System Design Leadership:

• Lead the design and development of engine and airframe systems and components beginning with first-principles engineering analysis.
• Develop engine specifications and translate high-level requirements into robust, manufacturable mechanical designs.
• Perform and/or define analytical requirements including FEA, CFD, fatigue life prediction, durability assessment, and engine performance simulation and optimization.
• Execute stack-up tolerance analyses to ensure designs meet fit, form, and functional requirements.
• Prepare detailed engineering drawings in accordance with ASME drafting standards, including advanced GD&T application.

Validation & Reliability Engineering:

• Conduct and lead Design Failure Mode & Effects Analysis (DFMEA) activities.
• Develop validation requirements, test standards, and qualification protocols for engines and subsystems.
• Analyze test data and implement design improvements to meet durability, reliability, and performance objectives.
• Apply Design for Six Sigma (DMAIC methodology) to reduce variation and improve product robustness.

Manufacturing & Cost Optimization:

• Design for manufacturability and assembly (DFMA), ensuring efficient production processes and minimized lifecycle cost.
• Select appropriate materials and manufacturing processes considering strength, fatigue, heat transfer, corrosion resistance, longevity, and cost.
• Design to achieve the lowest manufacturing cost consistent with performance, reliability, and FAA certification standards (e.g., 14 CFR Part 23 / Part 33 as applicable).
• Support prototype builds and leverage rapid prototyping methods to accelerate development cycles.

Collaboration & Technical Leadership:

• Proactively collaborate with design engineers, drafters, technicians, suppliers, and program managers to optimize system performance and reliability.
• Manage complex engineering projects to successful technical and schedule completion.
• Provide technical mentorship and coaching to junior engineers and cross-functional team members.
• Stay current with emerging materials, advanced manufacturing technologies, and evolving propulsion trends.

Required Qualifications:

• Bachelor of Science in Mechanical Engineering or equivalent from an accredited four-year university.
• 10+ years of progressive engine engineering experience, including rotating assemblies and integrated propulsion systems.
• Strong proficiency with analytical and simulation tools (FEA, CFD, fatigue, performance modeling).
• Advanced 3D CAD modeling proficiency (Solid Works or equivalent).
• Experience supporting or leading rapid prototyping and prototype development programs.
• Demonstrated ability to manage engineering projects from concept through production readiness.

Preferred Qualifications:

• Membership in professional engineering organizations such as SAE International or similar.
• Advanced engineering degree (MS or PhD) or relevant certification.
• Six Sigma Green Belt certification.
• Experience with compression ignition (diesel or Jet-A fueled) engines.
• Concept development and early-stage prototype engineering experience.
• Knowledge of FAA certification regulations and compliance processes.
• Demonstrated passion for engines, high-performance technology, innovation, and aviation.

Core Competencies:

• Systems architecture and propulsion integration
• High-speed rotating machinery expertise
• Requirements management and validation planning
• DFMEA and reliability engineering
• Design for manufacturability & cost optimization
• Technical leadership and mentorship
• Data-driven decision-making and structured problem solving

Work Environment: This position operates in a collaborative engineering environment with regular interaction in laboratory, test cell, and prototype build settings. The role may require hands-on involvement in development testing and production transition activities. This is a high-impact leadership role for an engineer who is driven by innovation, precision, and the pursuit of next-generation engine performance.

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