Mechanical Designer & FEA Analysis

Job Description

The position involves creating detailed CAD models and drawings, performing finite element simulations, preparing technical documentation, and collaborating closely with manufacturing, testing, and integration teams throughout the development lifecycle.

Key Accountabilities

• Develop mechanical designs for aerospace structures, propulsion systems, test articles, ground support equipment and related hardware. Prepare 3D CAD models, assemblies and detailed engineering drawings.
• Support the design of lightweight, manufacturable and structurally efficient components. Ensure mechanical designs meet functional, structural, interface and integration requirements.

• Perform FEA simulations to assess stress, deformation, stiffness, buckling, modal response and structural margins. Define appropriate boundary conditions, loads, constraints and material models for aerospace applications.
• Prepare clear FEA reports including assumptions, methodology, results, margins of safety and recommendations.

• Prepare manufacturing drawings with appropriate dimensions, tolerances, GD&T, surface finish, materials and inspection requirements. Ensure designs are suitable for machining, fabrication, welding, and assembly processes as applicable.
• Apply tolerance stack-up principles to ensure proper fit, alignment and assembly of aerospace components. Coordinate with manufacturing teams and vendors to resolve design-for-manufacturing issues.

• Support verification of mechanical designs against requirements, standards and test conditions. Prepare technical documentation including design reports, analysis reports, interface control documents, BOMs and assembly instructions.
• Support design reviews including concept reviews, PDR, CDR and manufacturing readiness reviews. Ensure traceability between requirements, design decisions, analysis results and final drawings.

• Work closely with propulsion, structures, simulation, manufacturing, instrumentation and test teams. Support test article preparation, assembly, integration and troubleshooting.
• Coordinate with external suppliers and internal stakeholders to ensure technical requirements are understood and implemented.

• Bachelor's degree in Mechanical Engineering, Aerospace Engineering, or a related field, with 3–7 years of relevant experience in mechanical design and structural analysis.
• Strong proficiency in 3D CAD modelling, assembly design, and preparation of manufacturing drawings for aerospace or high-performance engineering hardware.
• Practical experience performing FEA for metallic and/or composite structures, including static, vibration, buckling, thermal, or pressure load cases.
• Good understanding of manufacturing processes, tolerancing, GD&T, tolerance stack-up, materials, fasteners, joints, and design for manufacturing.
• Ability to prepare clear technical documentation, including design reports, FEA reports, BOMs, interface documents, and drawing packages.
• Experience supporting design reviews, prototype manufacturing, integration, testing, and correlation of analysis results with test data.