Senior Mechanical​/Aerospace Engineer

The Role You will take a physical aircraft part with missing or incomplete data and turn it into a validated, procurement-ready design. That means measuring it, modeling it, analyzing it, documenting it, and defending it to government engineering authorities.

This is a senior, hands‑on role. You will lead projects from part in hand to TDP delivery, mentor junior engineers and interns, and write the technical reports our customers rely on to approve new sources of supply. You will also help scope and estimate new work for proposals.

US Citizenship is required.

• Lead reverse engineering of mechanical and electromechanical aircraft components, including actuators, brakes, housings, structural parts and ground support equipment.
• Plan and perform dimensional inspection using CMMs, 3D laser and structured-light scanners, and precision hand tools.
• Process scan and point‑cloud data into accurate models and establish critical dimensions, datums and tolerances.
• Identify materials, finishes, coatings and processes, coordinating material analysis with outside labs as needed.
• Build parametric 3D solid models and assemblies in Solid Works.
• Create production drawings to ASME Y14.5 (GD&T) and Y14.100 / MIL-STD-31000 TDP requirements.
• Perform engineering analysis (tolerance stack‑ups, stress, fit and function) to substantiate designs.
• Understand how to read, develop, and incorporate Geometric Dimensioning and Tolerancing (GD&T) on manufacturing drawings based on metrology results and the function of each feature.
• Support first article, qualification and test planning with manufacturing and test partners.

• Write clear technical reports, engineering analyses, test plans and contract deliverables for customer review.
• Present findings and answer questions from Air Force, Army, Navy and DLA engineering authorities.
• Maintain configuration control and traceability of engineering data under our ISO 9001 quality system and ITAR/CUI handling rules.

• Lead project schedules and technical execution on multiple concurrent efforts.
• Mentor junior engineers and engineering interns.
• Develop technical approaches, labor estimates and Rough Order of Magnitude (ROM) costs for proposals.

• B.S. in Mechanical Engineering from an ABET-accredited program.
• 6–10 years of engineering experience on military aerospace systems (aircraft, components, sustainment or depot support).
• Hands‑on reverse engineering experience, including metrology with CMMs, 3D modeling, and creating manufacturing 2D drawings.
• Advanced 3D solid modeling and drawing skills in a major CAD package;
  Solid Works strongly preferred.
• Working knowledge of GD&T per ASME Y14.5 and engineering drawing standards.
• Strong technical writing skills, with examples of technical reports or engineering analyses you authored.
• U.S. citizenship, required for access to ITAR‑controlled technical data.
• Ability to lead projects independently and communicate directly with government customers.

• Experience developing TDPs to MIL-STD-31000 and supporting source approval requests (SARs) or engineering change proposals.
• Experience in electronic and avionics design.
• Experience in novel mechanical and electrical designs for non-government clients.
• Familiarity with scan‑to‑CAD software such as Geomagic Design X, Poly Works or similar.
• Experience with FEA (Solid Works Simulation, ANSYS or similar) and tolerance analysis.
• Background in actuators, landing gear, brakes, hydraulics or flight control components.
• Exposure to additive manufacturing design and qualification.
• Experience writing cost estimates, basis of estimates or technical volumes for government…