Principal Propulsion Mechanical Systems Analyst

AIRO Group Holdings, Inc. • Montreal, QC

4d • CA$130,000 - CA$155,000

About The Position

As a Level 4 Principal Propulsion Mechanical Systems Analyst, you will act as a critical technical anchor, leading the structural design, drive-coupling mechanisms, and mechanical reliability profiles of the main slowed-rotor mast assembly and the wing-mounted propulsors. In this advanced role, you are responsible for leading the integration of major rotating and structural powertrain systems, mitigating technical risk across complex multi-disciplinary boundaries, and managing comprehensive technical design reviews. You will guide sub-system design maturity from initial layout through finite element validation, environmental qualification, and prototype flight readiness.

Requirements

• Extensive background in the structural and mechanical design of aircraft turbomachinery, high-performance power transmissions, or rotorcraft drive systems.
• Complete proficiency using enterprise 3D CAD modeling software (such as Dassault 3DEXPERIENCE or Catia V5) alongside advanced Finite Element Analysis (FEA) solvers.
• Deep knowledge of structural fatigue mechanics, joint physics, bearing lifetime calculations, and metallic material properties (aluminum, titanium, and steel alloys).
• Practical familiarity implementing non-linear mechanical vibration-dampening systems, dynamic balancing metrics, and strain profiling instrumentation arrays.
• Demonstrated experience guiding complex aerospace mechanisms or high-load mechanical systems through rigorous manufacturing, test verification, and formal technical design reviews.
• Strong leadership traits with the ability to define multi-system boundaries, resolve challenging geometric interference problems, and mitigate development risk across disciplines.

Nice To Haves

• Ability to read, write, and understand French

Responsibilities

• Lead the structural configuration, mechanical sizing, and layout design of the main slowed-rotor mast assembly, main rotor shafts, and wing propulsor housings.
• Design and optimize precision drive-coupling mechanisms, heavy reduction gearboxes, high-torque dynamic joints, and safety-critical bearing assemblies.
• Establish structural load transfer paths to safely distribute massive rotor thrust, cyclic loading, and propulsion moments into the primary metallic fuselage.
• Develop, mesh, and execute comprehensive structural Finite Element Analysis (FEA) to assess fatigue life, static margins of safety, and dynamic load limits under severe operating conditions.
• Oversee dynamic strain profiling and configure advanced vibration-isolation bushings and dampening mounts to mitigate high-frequency rotor harmonics and resonance.
• Coordinate cross-functional interface definitions with aerodynamic, electrical powertrain, and safety teams to align structural limits with platform weight and center-of-gravity envelopes.
• Direct technical design reviews, author subsystem qualification plans, and support civil aviation conformity documentation updates.

What This Job Offers

• Job Type: Full-time
• Career Level: Principal