Principal Mechanical Engineer - Flight

LEAP•Broomfield, CO

17h•Hybrid

About The Position

We are seeking a Principal Mechanical Engineer - Flight to own complex major flight assemblies from concept through release. This role serves as a technical leader within the mechanical team, mentoring junior engineers and collaborating closely with structures, propulsion, avionics, and manufacturing to drive successful flight outcomes. You will lead a technical team of 4–10 people to deliver consistent mechanical and structural design results, ensuring flight-ready documentation and CAD integrity.

Requirements

12+ years of experience in mechanical design for high-performance systems, preferably in the aerospace industry
Demonstrated ownership of major assemblies from concept through flight or production
Demonstrated leadership of small to medium size technical teams
Proficiency in 3D CAD software (preferably NX) and strong command of GD&T principles
Experience performing FEA and hand calculations to validate flight-critical hardware
Strong understanding of lightweight aerospace design best practices (material selection, structural efficiency, geometric optimization)
Proven experience applying DFM and DFA methodologies, with practical knowledge of fabrication techniques including welding, machining, and additive processes
Familiarity with PLM systems (preferably Teamcenter) and configuration management for large assembly designs
Organized, detail-oriented approach to CAD data management, BOM creation, revision control, and collaborative environments

Nice To Haves

Experience in high-growth, startup, or technically complex environments

Responsibilities

Own complex major flight assemblies to complete stages end-to-end.
Serve as a technical leader within the mechanical team and mentor junior engineers.
Work closely with structures, propulsion, avionics, and manufacturing to drive successful flight outcomes.
Lead a technical team of 4–10 people to deliver consistent mechanical and structural design results.
Manage and deliver all levels of design reports, designs, documentation, analyses, etc.
Develop and own 3D CAD models of primary flight hardware (Liquid Rocket Vehicle Stages, Payload Fairings, Complete Fluid Systems, etc.), taking assemblies from concept through release.
Perform hand calculations and FEA to validate designs, define load paths, and ensure compliance with stress and mass requirements.
Guide design standards, mentor junior engineers and designers, and contribute to architectural decisions impacting overall vehicle configuration.
Work cross-functionally with propulsion, avionics, GNC, and manufacturing to define and ensure interface control (bolting patterns, harness pass-throughs, thermal interfaces, tolerance stacks, etc.) meets system-level requirements.
Lead design reviews with internal teams and vendors.
Ensure hardware is DFM/DFA compliant and proactively resolve producibility risks.
Deliver BOMs and detailed component and assembly drawings that follow GD&T standards and aerospace best practices, ensuring unambiguous build and inspection criteria.
Maintain part libraries, revision histories, interface control documentation, and BOM accuracy within PLM systems, ensuring the engineering team operates from a single source of truth.

Benefits

Equity plan participation
401(k) plan with company matching
Professional development stipend
Flexible Time Off (PTO)
Paid holiday breaks
Two week long company winter breaks
Paid leave to support a family member, bond with a new child, or manage your own health needs
Comprehensive medical, dental, and vision coverage
Coverage for dependents
HSA available
Basic life insurance
Long-term disability insurance
Options to add extra coverage