Senior Mechanical Engineer/Designer - Flight

LEAP•Broomfield, CO

8d•Hybrid

About The Position

Own and Lead Flight Hardware Design: Develop and own 3D CAD models of primary and secondary flight hardware (fuselage sections, internal support frames, engine mounting structures, interfacing hardware, avionics housing, etc.), taking assemblies from concept through release. Drive Structural & Mass Optimization: Perform hand calculations and FEA to validate designs, define load paths, and ensure compliance with stress and mass requirements. Partner with Structures on advanced analysis and test correlation. Technical Leadership: Guide design standards, mentor junior engineers and designers, and contribute to architectural decisions impacting overall vehicle configuration. System-Level Collaboration: Work cross-functionally with propulsion, avionics, GNC, and manufacturing to ensure interface control (bolting patterns, harness pass-throughs, thermal interfaces, tolerance stacks, etc.) meets system-level requirements. Manufacturing Integration: Lead design reviews with internal teams and vendors. Ensure hardware is DFM/DFA compliant and proactively resolve producibility risks. Produce Flight-Ready Documentation: Deliver BOMs and detailed component and assembly drawings that follow GD&T standards and aerospace best practices, ensuring unambiguous build and inspection criteria. Own Configuration & CAD Integrity: 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.

Requirements

8+ 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
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 with composites or cryogenic designs for rocket flight hardware
Prior flight hardware release experience
Experience supporting integration, test campaigns, or flight readiness reviews

Responsibilities

Develop and own 3D CAD models of primary and secondary flight hardware
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
Work cross-functionally with propulsion, avionics, GNC, and manufacturing to ensure interface control 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
Maintain part libraries, revision histories, interface control documentation, and BOM accuracy within PLM systems