Senior Mechanical Design Engineer

Senior Mechanical Engineer Job Summary:

The Senior Mechanical Design Engineer is responsible for the design, development, and integration of mechanical systems for aircraft products. This role applies advanced engineering knowledge, analytical skills, and independent judgment to drive mechanical design, support testing and validation, and collaborate with cross-functional teams. The Senior Mechanical Design Engineer leads complex technical tasks, contributes to design strategy, and ensures mechanical solutions meet performance, manufacturability, quality, and reliability requirements.

Responsibilities and Duties:

• Develop, modify, and optimize 3D CAD models, detailed drawings, and assemblies to meet mechanical design objectives.

• Perform structural, thermal, and systems-level analysis to evaluate design performance and reliability.

• Contribute to system requirements definition, trade studies, subsystem design approaches, and verification/validation planning.

• Generate and review engineering documentation such as work orders, build guides, and process travelers, ensuring alignment with engineering intent and configuration control.

• Collaborate with manufacturing, quality, technicians, and other engineering disciplines to support design iterations and resolve technical challenges.

• Support test, verification, and validation of mechanical systems, documenting results and incorporating findings into design improvements.

• Maintain configuration control and documentation integrity using PDM/PLM systems.

• Participate in and provide input during design reviews, offering technical rationale, recommendations, and risk assessments.

• Identify design risks, propose mitigations, and implement improvements to enhance manufacturability, safety, and product performance.

• Mentor junior engineers and support development of engineering team skills.

Required Qualifications and Skills:

• Bachelor’s degree in mechanical engineering or closely related field; master’s preferred.

• 5–9 years of progressive mechanical engineering experience, preferably in aerospace or complex mechanical systems.

• Proficiency with SolidWorks or equivalent 3D CAD tools, including drawing creation and revision control.

• Strong understanding of mechanical systems, assemblies, structures, mechanisms, and materials.

• Hands-on experience with design for manufacturability (DFM/DFA) principles.

• Ability to work independently, exercise judgment, and manage complex engineering tasks.

• Strong organizational, communication, and collaboration skills.

• Proficiency in Microsoft Office Suite (Word, Excel, PowerPoint).

Desired Qualifications and Skills:

• Experience with composite materials, precision machining, or advanced fabrication methods.

• Knowledge of complementary disciplines such as stress analysis, dynamics, thermal analysis, or systems engineering.

• Familiarity with structured development processes, gated design workflows, or PLM systems.

• Experience with regulated quality standards such as ISO9001 or AS9100.

Comprehensive Benefits & Perks:

• Health & Wellness: Choose from three health, dental, and vision plans - including a 100% employer-paid option covering both employees and their families.

• Paid Time Off: Enjoy 120 hours of PTO, 80 hours accrued plus an additional 40 hours of holiday break pay in addition to Christmas Eve, Christmas Day, and New Year’s Day off.

• Life Insurance: $25,000 employer-paid life insurance policy, with the option to purchase additional coverage for employees and their families.

• Supplemental Coverage: Access optional benefits such as Critical Illness, Hospital Indemnity, Accident Insurance, and Critical Illness with Skin Cancer coverage.

• Health Savings Account (HSA): Take advantage of a tax-advantaged HSA to manage medical expenses.

• Retirement Savings: 401(k) with a company match to support your financial future.

• Paid Holidays: Enjoy 9 paid holidays throughout the year.

• Work Environment: A casual dress code, complimentary snacks, and a welcoming company culture.

• Ideal Location: Work in an area that offers an outstanding quality of life - a perfect place to live, work, and play!

Company Overview:

Empirical Systems Aerospace, Inc (ESAero) is a leader in aerospace engineering, product development, and manufacturing, dedicated to delivering high-quality, innovative, and cost-effective solutions to the industry. We specialize in cutting-edge system design, rapid product development, precision manufacturing, comprehensive testing, and technology demonstrations to support the evolving needs of the aerospace community. Committed to excellence, on-time delivery, and continuous growth, we invest in infrastructure to expand our manufacturing and aftermarket capabilities while maintaining the highest standards of engineering services.

At ESAero, we don’t just build products, we engineer solutions that propel the aerospace industry forward. This position is fully on-site at ESAero in San Luis Obispo, CA

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ESAero is an equal opportunity employer.
E-Verify participation required for employment.
Must present proof of authorization to work in the United States.
Must be able to pass background check and drug test.
Pay Range: $110k - $140k Salary/Exempt