Sr. Mechanical Engineer

Job Summary

The Senior Mechanical Engineer converts system requirements into complete mechanical products. The position holder owns products and subassemblies from requirement to field support, with minimum supervision. Aerostructures, aerodynamics and flight dynamics are not in the primary scope of this role. Dedicated CAE engineers do the detailed simulation work.

Responsibilities

• Interpret requirements, develop concepts and do trade studies. Take each design through preliminary and detailed design.
• Create stable and maintainable CAD models of parts, assemblies and mechanisms. Capture design intent, interfaces, tolerances and assembly logic, not only the correct shape. Do motion, interference, clearance and access checks, and estimate mass, centre of gravity and inertia.
• Drawings and BOMs. Create and release production drawings and engineering BOMs through PDM/PLM. Apply GD&T, fits, finishes, materials, heat treatment, coatings, joining and torque requirements, and critical-to-function characteristics.
• Calculations. Do first-principles calculations for loads, stresses, deflection, joints, buckling, fatigue, thermal expansion, shock and natural frequencies. Use them to guide each design before detailed CAE.
• CAE interface. Give the CAE team correct loads, interfaces, materials, operating conditions and acceptance criteria. Check that the results are physically reasonable, and put the design changes into the CAD. Do basic linear static, modal and thermal analyses when necessary.
• Reviews. Review the CAD models and drawings of other engineers for design intent, interfaces, tolerance stacks, manufacturability, inspectability and serviceability. Present your designs at peer reviews, PDR, CDR and vendor DFM reviews, and close the review actions.
• Vendors and manufacture. Work directly with vendors on manufacturability, tooling, tolerances, inspection, cost, lead time, deviations and non-conformances. Support prototype builds, First Article Inspection and production. Design for low unit cost and rate production.
• Test and qualification. Design test fixtures, prepare test items, and support development, qualification and acceptance tests. Do pre-test and post-test inspections, failure investigation, root-cause analysis and corrective action.
• Flight trials and field. Support ground tests, flight trials and field operations. Find the cause of each hardware problem quickly and implement the design change.
• Configuration. Raise and implement ECRs and ECOs. Control the revisions, effectivity and interchangeability of your parts.
• Customer and field. Support customer technical reviews, customer inspections and delivery documentation. Investigate field failures and implement product improvements.
• Guidance. Guide junior engineers and check their work.

Requirements

Minimum Experience (Years)

4-6 years of mechanical product design.

HyPrix prefers this experience, but it is not mandatory. Demonstrated capability is more important than years.

Required Skills

• Product ownership. You personally designed and released real products that were manufactured, assembled, inspected, tested, qualified, delivered to a customer and supported after delivery. Experience limited to concept design, isolated CAD work, analysis support or prototype fabrication is not sufficient.
• CAD. Strong hands-on capability in CATIA, Creo, Siemens NX or SolidWorks. This includes parametric parts, complex assemblies, skeleton-based design, configurations, sheet metal, machined, welded, cast and moulded parts, and mechanisms.
• Drawings and GD&T. Ability to create and check production drawings independently, to ASME Y14.5 or ISO GPS. You know that the released drawing is a technical contract between design, manufacture, inspection, quality and the vendor.
• Tolerance engineering and DFMEA. Worst-case tolerance-stack analysis, tolerance allocation and DFMEA. You connect each tolerance to product function, process capability and inspection method.
• First-principles calculations. Load paths, combined stresses, deflection, joint and fastener loads, contact stresses, buckling, fatigue, thermal expansion, shock, natural frequencies and margins of safety.
• Vibration and shock design. Sine and random vibration, PSD profiles, Grms, resonance, mode separation, damping, mounting stiffness and SRS. You know that static strength alone does not show that a design is suitable for a vibration environment.
• CAE understanding. The inputs, assumptions and limits of linear static, modal and basic thermal FEA, and correlation with hand calculations.
• Motion systems and alignment. Bearing selection, life, preload and fits. Datums, locating features, dowels, shims and alignment retention under temperature and vibration.
• Military environmental design. Design for temperature, thermal cycling, humidity, dust, salt fog, altitude, shock and vibration. Selection of materials, heat treatments, coatings, seals and adhesives.
• Manufacture. Practical knowledge of CNC machining, sheet metal, welding, casting, moulding, additive manufacturing, heat treatment, surface treatment and First Article Inspection. Hands-on prototype build experience, and a record of root-cause investigations of manufacturing and hardware defects.
• Configuration management. Part-number discipline, revision control, ECR and ECO processes, and non-conformance control.
• A bachelors degree in mechanical, aerospace or production engineering.
• Ability to travel to vendors, test ranges and customer sites when necessary.

Advantageous Skills/Qualifications

• Experience with electro-optical gimbals, sensor mounts, actuators or other precision motion systems.
• Experience with missile, UAV, munition or other airborne defence hardware.
• Practical application of MIL-STD-810, DO-160, MIL-STD-461.

Disclaimer: This job posting has been aggregated from external source. Role details, content, and availability are subject to change. Applicants are advised to confirm the latest information directly on the company website before applying.