Senior Mechanical Engineer

Senior Mechanical Engineer Overview:

The Senior Mechanical Engineer is responsible for the design, analysis, and development of complex mechanical systems from concept through production release. In this role, you will lead the detailed mechanical design of products and subsystems, perform advanced engineering analyses, and ensure designs meet performance, reliability, and manufacturability requirements. You will work closely with cross-functional teams including Electrical, Software, Manufacturing, Quality, and Supply Chain to deliver robust, production-ready solutions.

This position requires strong hands-on design experience combined with deep analytical capability in structural FEA, vibration and modal analysis, and heat transfer, as well as practical expertise in injection-molded plastic design and production manufacturing processes.

Experience:

10+ years

Education:

BS or MS in Mechanical or Aerospace Engineering

Key Duties:

Own the mechanical design and detailed implementation of product subsystems from concept through sustaining

Develop and maintain mechanical system architectures, layouts, and detailed component designs

Perform advanced structural analysis (FEA) to validate strength, stiffness, fatigue, and durability requirements

Conduct vibration and modal analysis to evaluate dynamic response, resonance, and environmental loading

Perform thermal and heat transfer analysis to ensure safe and reliable operation under all operating conditions

Translate high-level product requirements into clear, traceable mechanical requirements and design solutions

Lead design trade studies to down-select materials, architectures, and manufacturing processes

Design for injection molding, including part geometry, draft, gating considerations, tolerances, and material selection

Apply DFM/DFA and DFT best practices to optimize cost, quality, and manufacturability

Create and maintain accurate CAD models, drawings, and GD&T using Solid Works or equivalent CAD tools

Support prototype builds, testing, and design iteration based on verification and validation results

Collaborate with suppliers and contract manufacturers to review designs, tooling, and production readiness

Support root-cause analysis and corrective actions for test, quality, or manufacturing issues

Mentor junior engineers and provide technical guidance on best design and analysis practices

Maintain mechanical documentation and bills of materials (BOMs) within the PLM system throughout the product lifecycle

Key Background Knowledge:

Strong experience in mechanical system and component design for complex products

Demonstrated expertise in structural FEA, vibration analysis, and modal testing correlation

Solid understanding of heat transfer and thermal management in electromechanical systems

Proven experience designing injection-molded plastic components for high-volume production

Experience with metals, plastics, fasteners, adhesives, and surface treatments

Proficiency in Solid Works, PDM, and PLM systems

Experience working with test teams to correlate analysis results with physical testing

Demonstrated ability to work effectively across cross-functional teams and influence technical decisions

Strong documentation, communication, and technical leadership skills

Proficient understanding of engineering principles, best practices, and design processes

Experience supporting products through production ramp and sustaining engineering

Preferred Qualifications:

Familiarity with supplier tooling reviews and injection mold qualification

Previous experience with avionics or UAVsExperience with propulsion systems (propeller design and motor selection)
Background Check This position will require successfully completing a post-offer background check. Qualified candidates with a criminal history will be considered and are not automatically disqualified, consistent with federal and state law.

EEO and ITAR/EAR Work Authorization Disclosure Red Cat Holdings provides equal employment opportunities (EEO) to all employees and applicants for employment and prohibits discrimination and harassment of any type without regard to race, color, religion, age, sex, national origin, disability status, genetics, protected veteran status, sexual orientation, gender identity or expression, or any other characteristic protected by federal, state or local laws.

This position requires direct or indirect access to hardware, software, technology or technical data controlled under the International Traffic in Arms Regulations (ITAR) and the…