Mechanical Design Engineer, Propulsion Integration

Industry: Hybrid-Electric Aerospace / Advanced Aviation

Location: San Jose

About:

This role sits within a clean-sheet propulsion and vehicle integration programme based in California.

It is not a minor modification effort. The team is rethinking propulsion architecture at aircraft level, including generator integration, high-power electronics, energy distribution, and advanced thermal management, layered onto an existing aircraft platform.

The programme also carries a defence-focused dimension, with applications spanning ISR, distributed operations, and mission-adaptable configurations. Technically, this is a multidisciplinary systems integration challenge suited to engineers who want ownership at vehicle level rather than remaining at isolated component level.

• Lead the design of structural elements and oversee propulsion system integration on full-scale prototype aircraft
• Develop detailed metallic components and assemblies supporting propulsion attachment, structural interfaces, and overall system integration
• Take ownership of the end-to-end prototype lifecycle including requirements definition, design, BOM creation, sourcing, assembly, and validation
• Carry out structural calculations and hand analyses to validate load paths, safety margins, and interface performance
• Perform finite element analysis on metallic structures and mounting systems to ensure design robustness
• Engage with external suppliers to evaluate and select suitable COTS hardware such as mounts, brackets, and fastening solutions
• Define and execute verification and validation test strategies, ensuring designs are proven through rigorous testing
• Produce and review detailed engineering drawings, specifications, and technical documentation
• Contribute to requirements capture, development, and traceability documentation
• Manage supply chain activities and drive procurement efforts for owned hardware
• Work closely with cross-functional engineering teams across multiple disciplines

• 5–15 years of relevant engineering experience
• Bachelor’s degree in Mechanical Engineering or related discipline
• Experience integrating and/or designing flight-critical hardware attached to primary aircraft structure
• Strong proficiency in CAD tools such as NX or Solid Works, with NX preferred
• Experience managing large CAD assemblies within PLM environments such as Teamcenter
• Solid understanding of load analysis, free body diagrams, and FEA methodologies
• Demonstrated experience designing complex metallic components and welded assemblies
• Strong knowledge of GD&T and creation of manufacturing-ready drawings
• Familiarity with aerospace hardware specifications and standards
• Hands‑on engineering experience across multiple technical domains, particularly metallic and composite structures
• Clear and effective communication skills

• Degree in Aerospace, Mechanical, Electrical Engineering, or equivalent technical field
• Experience working with electric propulsion, powertrain systems, or broader aerospace systems
• Strong understanding of full product development cycles including design phases, manufacturing, and global supply chain coordination
• Experience using tools such as Jira and Confluence for project tracking and documentation
• Background supporting vehicle development from early prototype phases through certification and production
• Familiarity with Part 23 certification requirements and/or ARP
  4754A processes