Senior Mechanical Design Engineer

ASI is seeking a highly skilled Senior Mechanical Design Engineer to support complex aircraft modification, prototyping, and integration projects within the Aircraft Prototype Systems Division (APSD). This position is located onsite at NAS Patuxent River, MD and is not remote eligible. Responsibilities:

• Develop advanced 3D CAD models using PTC Creo, including complex geometries, large assemblies, skeleton-based architectures, surfaces, and shrink-wrap techniques

• Create, review, and manage Technical Data Packages (TDPs) compliant with MIL-STD-31000 and ASME drafting standards including ASME Y14.100, Y14.24, Y14.35, and Y14.5 GD&T requirements

• Perform classical mechanical and structural hand calculations for brackets, fasteners, margins of safety, and airworthiness substantiation to support flight clearance documentation

• Develop engineering drawings, analyses, and documentation in support of airworthiness, referencing Mil-HDBK-516, NAVAIRINST 13034.1, and NAWCADINST 13050.1

• Utilize PTC Windchill for configuration management, product structure control (WTParts), CAD data management, and change-control workflows including ECPs and ECNs

• Lead and mentor junior engineers and technicians, providing direction on CAD standards, GD&T, drafting practices, and workload prioritization

• Apply manufacturing knowledge related to sheet metal and machining processes, including CNC, lathes, mills, press brakes, and water jets, ensuring designs are optimized for fabrication and installation

• Work independently to execute complex, non-routine design tasks with minimal supervision, resolving technical issues and shaping engineering solutions on accelerated timelines

Required Qualifications:

• Bachelor’s or Master’s degree in Mechanical or Aerospace Engineering from an accredited U.S. institution (ABET)

• 10+ years of experience in aircraft mechanical design, production support, or structural/mechanical modification work

• Expert-level proficiency in PTC Creo Parametric modeling, including surfaces, skeletons, and large assembly management

• Strong understanding and practical application of ASME Y14.x drafting standards and ASME Y14.5 GD&T

• Ability to perform classical structural/strength hand calculations relevant to aircraft modifications

• Demonstrated experience with Windchill PLM workflows and formal configuration-management processes

• Ability to work independently, manage complex engineering tasks, and mentor junior team members

• Familiarity with manufacturing processes to ensure designs are producible and installable in sheet-metal and machining environments