Mechanical Structural Design Engineer

The role owns micro-jet engine mechanical work packages end-to-end—from initial requirements capture, concept trade studies, and 3D CAD modeling through to drawing release, manufacturing, engine build, rig/engine testing, and design maturation. Roles & Responsibilities:Micro-Jet Mechanical Design & Technical Ownership: Own micro-jet engine mechanical work packages across requirements capture, concept trade studies, preliminary sizing, detailed design, drawing release, manufacturing, engine build, testing, and maturation. Develop and integrate 3D CAD models and assemblies for compressors, turbines, rotors, stators, shafts, bearings, housings, casings, seals, flanges, and nozzles. Structural, Thermal & Rotating-Machinery Analysis: Conduct analytical calculations and FEA for static/rotating loads, nonlinear contact, bolted joints, buckling, modal/vibration response, pressure, thermal/thermo-mechanical loads, fatigue, and durability. Evaluate centrifugal/bending stresses, thermal growth, running clearances, rub risks, high-temperature material behavior (creep, fatigue, oxidation), and rotor dynamics (Campbell diagrams, critical speeds, bearing/support stiffness). Product Definition, Manufacturing & Assembly: Create controlled 3D models and manufacturing drawings using GD&T (ASME Y14.5 / ISO GPS), tolerance stacks, and datum schemes. Define specs for joints (bolted, clamped, splined, press-fit) and coordinate with manufacturing/suppliers on machining, casting, additive manufacturing, welding, brazing, balancing, and assembly tooling. Test Hardware, Troubleshooting & Test-Correlation: Design test-engine hardware and instrumentation provisions (pressure, temperature, vibration, strain). Support engine assembly, build-readiness, rig/engine testing, commissioning, teardown, and root-cause troubleshooting for rub, clearance, vibration, or structural anomalies, correlating test results with analytical models. Integration, Supplier Coordination & Reviews: Lead mechanical/structural work packages within multidisciplinary teams, coordinate supplier technical packages and deviations, mentor junior engineers, and deliver formal substantiation packages at PDR, CDR, TRR, and post-test reviews. Required Skills & Qualifications:Education & Experience: Bachelor’s or Master’s degree in Mechanical, Aerospace Engineering, or a related field with 7–12 years of relevant experience owning hardware through design, build, test, and maturation. CAD & Product Definition: Advanced proficiency in 3D CAD platforms (Siemens NX, CATIA, Creo, or SolidWorks) and PDM/PLM systems. In-depth mastery of GD&T (ASME Y14.5 or ISO GPS), tolerance stack-up analysis, and fits. FEA & Simulation Tools: Hands-on expertise with FEA software (Ansys Mechanical, Abaqus, Nastran, or equivalent) covering linear/nonlinear static, contact, bolt preload, modal/vibration, thermal-structural, and fatigue/durability analyses. Domain Knowledge: Deep understanding of gas turbine mechanical architecture (compressor/turbine rotors, stators, bearings, shafts, seals, casings), solid mechanics, heat transfer, high-temperature materials/coatings, and rotor dynamics / balancing (Campbell diagrams, critical speeds). Manufacturing & Testing: Working knowledge of precision aerospace manufacturing processes (machining, additive manufacturing, casting, brazing), assembly/inspection workflows, instrumentation installation, and engine test/rig troubleshooting.