Senior Mechanical Engineer in Crozet

Job DescriptionJob DescriptionSalary:

Why This Role Exists

Engineering Services is capacity-constrained, resulting in unbilled customer contracts and missed delivery timelines. Current senior engineers are oversubscribed across internal R&D and customer programs. This role adds dedicated senior-level mechanical engineering capacity to ensure customer deliverablesparticularly for the Aerovel and Wing programsare met on schedule and to spec.

Role Summary

The Senior Mechanical Engineer leads mechanical design and analysis for major subsystems across customer and internal programs. You will own the full mechanical design lifecyclefrom concept through releaseusing SolidWorks/PDM, perform thermal and structural simulations (FEA/CFD) to validate designs, and manage the technical data packages required for AS9100-compliant hardware releases.

Core Responsibilities

• Lead mechanical design for major subsystems (enclosures, thermal management, structural mounts) using SolidWorks and SolidWorks PDM.
• Conduct FEA and CFD analysis to validate heat rejection, vibration response, and structural integrity for high-power avionics enclosures.
• Own and manage technical data packages (TDPs) for customer and internal programs, ensuring AS9100-compliant documentation and revision control.
• Collaborate with electrical engineering on packaging, connector placement, and thermal interface design for power electronics assemblies.
• Support prototype fabrication and first-article inspection, including GD&T callout definition and vendor communication.
• Drive design reviews (PDR, CDR) for mechanical subsystems, presenting analysis results and trade studies to cross-functional stakeholders.
• Mentor junior mechanical engineers and co-ops on design standards, simulation workflows, and documentation practices.

Required Qualifications

• 5+ years of experience in mechanical design engineering, with a focus on electronic enclosures, thermal management, or electromechanical systems.
• Expert-level proficiency in SolidWorks (parts, assemblies, drawings) and SolidWorks PDM or equivalent PLM system.
• Demonstrated experience with FEA (ANSYS, SolidWorks Simulation, or equivalent) for structural and thermal analysis.
• Strong command of GD&T (ASME Y14.5) and mechanical drawing standards.
• Experience managing technical data packages in a configuration-controlled environment.
• BSME or equivalent; MSME .

Qualifications

• Experience designing for aerospace or defense applications with DO-160 or MIL-STD environmental qualification.
• CFD analysis experience (ANSYS Fluent, FloTHERM, or equivalent) for forced-air and liquid cooling systems.
• Familiarity with AS9100 design control and document release processes.
• Experience with DFM/DFA for sheet metal, CNC machining, and injection molding.