Mechanical Engineer

Allocor Tech•Crozet, VA

16d•$100,000 - $135,000•Onsite

About The Position

Join a fast-scaling aerospace startup and set the standard for mechanical engineering excellence. Allocor.tech designs and manufactures mission-critical power electronics and avionics including motor controllers, battery management systems, power distribution, flight control, and flight termination systems for unmanned aerial vehicles (UAS/UAM) and unmanned maritime platforms. Our customers are leaders in advanced air mobility, uncrewed aircraft, and electric watercraft. The team brings deep experience from organizations including Northrop Grumman, L3Harris, Sierra Space, and Aurora Flight Sciences. We are a team of approximately 35 people generating roughly $10M in annual revenue. We recently closed a $6.0M Series A and are projecting 100–200% revenue growth over the next year as we scale production, expand our customer base, and professionalize the business beyond its engineering-led roots. This is a pivotal moment: we are building the technical depth and process rigor required to support rapid, disciplined growth while protecting the speed and agility that got us here. The Mid-Level Mechanical Engineer will own detailed mechanical design work for high-reliability avionics and power electronics subsystems, with a focus on enclosures, thermal management, and structural interfaces for hardware that is already flying on customer UAS, eVTOL, and unmanned platforms. This is a hands-on role for an engineer who thrives in a fast-moving environment and wants real ownership of designs that reach flight hardware. You will design, analyze, document, and support bring-up of mechanical solutions while helping strengthen the standards and processes that will scale with Allocor.tech.

Requirements

Bachelor’s degree in Mechanical Engineering or equivalent (MS a plus).
3–6 years of mechanical design engineering experience focused on electronic enclosures, thermal management, or electromechanical systems.
Strong proficiency in SolidWorks (parts, assemblies, drawings) and SolidWorks PDM (or equivalent PLM/configuration management system).
Demonstrated experience performing structural and/or thermal FEA (SolidWorks Simulation, ANSYS, or equivalent).
Solid command of GD&T per ASME Y14.5 and mechanical drawing standards.
Experience creating and managing technical data packages in a configuration-controlled environment.

Nice To Haves

Experience designing for aerospace or defense applications with DO-160 or MIL-STD environmental qualification requirements.
CFD analysis experience (ANSYS Fluent, FloTHERM, or equivalent) for forced-air or liquid cooling systems.
Familiarity with AS9100 design control, document release processes, and quality management expectations.
Hands-on DFM/DFA experience with sheet metal, CNC machining, and injection molding.
Prior work supporting power electronics, avionics, or high-reliability flight hardware.

Responsibilities

Design mechanical solutions for enclosures, thermal management systems, and structural mounts using SolidWorks and SolidWorks PDM.
Perform structural and thermal FEA to validate heat rejection, vibration response, structural integrity, and environmental performance for high-power avionics hardware.
Create complete technical data packages (TDPs) that meet AS9100 expectations, including proper revision control and release processes.
Collaborate closely with electrical engineering on packaging, connector placement, thermal interface materials, and integration of power electronics assemblies.
Support prototype fabrication, first-article inspection, GD&T definition, and vendor communication to ensure designs are manufacturable and meet requirements.
Participate in mechanical design reviews (PDR, CDR), presenting analysis results, trade studies, and risk assessments to cross-functional stakeholders.
Contribute to the continuous improvement of design standards, simulation practices, GD&T application, and configuration-controlled documentation.
Work effectively across Engineering, Operations, and external suppliers to keep programs on aggressive timelines.