Senior Mechanical Design Engineer - Aviation

SUMMARY:

We are seeking an exceptionally skilled and forward-thinking Senior 3D Designer to lead the mechanical and aesthetic development of next-generation pilot helmets. In this role, you will be responsible for designing cutting-edge headborne systems for military, commercial, and generational aviation applications.

The ideal candidate possesses an elite level of mastery in SolidWorks, with a specific, proven track record in advanced surface modeling (surfacing). You will translate complex ergonomic data, industrial design concepts, and optical/electronic integration requirements into high-performance, manufacturable, and life-saving products.

Key Responsibilities

1. Advanced Surface Modeling & Product Design

• Execute complex, high-class surface modeling in SolidWorks to create organic, aerodynamic, and ergonomically precise helmet shells and components.
• Integrate advanced sub-systems into the helmet architecture, including heads-up displays (HUDs), night vision goggle (NVG) mounts, oxygen mask receivers, communications gear, and life-support systems.
• Maintain master models and top-down design assemblies to ensure seamless component integration and parametric robustness.

2. Cross-Functional Collaboration

• Partner closely with Industrial Designers to transform conceptual sketches and aesthetic visions into production-ready 3D geometry without losing design intent.
• Collaborate with Aerospace, Optical, and Human Factors Engineers to satisfy strict weight, balance, center of gravity (CG), and impact-mitigation requirements.
• Work with manufacturing partners to optimize designs for injection molding, carbon fiber/composite layups, and additive manufacturing (3D printing).

3. Design Validation & DFM

• Conduct rigorous Design for Manufacturability (DFM) and Design for Assembly (DFA) reviews.
• Utilize SolidWorks Simulation tools (or collaborate with FEA teams) to ensure structural integrity against high-GG environments, impact, and ballistic requirements.
• Generate comprehensive, high-fidelity 2D engineering drawings with precise Geometric Dimensioning and Tolerancing (GD&T) to ensure strict quality control.

Required Qualifications & Skills

Technical Expertise

• SolidWorks Mastery: Minimum of 6 years of heavy daily use, with expert-level capability in advanced surfacing features (e.g., Loft, Boundary Surface, Fill Surface, Knit, and complex filleting).
• Organic Shapes & Ergonomics: Proven experience designing products that interface directly with human anatomy (e.g., helmets, prosthetics, wearable tech, or high-end sporting goods).
• Materials Knowledge: Deep understanding of advanced composites (Kevlar, Carbon Fiber), high-impact polymers, and lightweight metals (Titanium, Aluminum).

Experience & Education

• Experience: 7 years of experience in 3D mechanical design/product development. Experience in aerospace, defense, or high-performance protective equipment is highly preferred.
• Education: Bachelor’s degree in Mechanical Engineering, Industrial Design, Aerospace Engineering, or a highly related technical field (equivalent exceptional portfolio/experience considered).

Regulatory Compliance Note: Due to the military nature of our programs, candidates must be US Citizens or Permanent Residents and eligible to obtain a US Security Clearance (ITAR compliant).

Preferred Attributes

• Attention to Detail: An uncompromising eye for seamless curvature continuity (G1G1, G2G2, and G3G3 continuity transitions).
• Problem Solver: Ability to navigate the tight spatial constraints of integrating electronics and optics into a lightweight, wearable envelope.
• Generational Vision: Interest in emerging aviation trends, such as augmented reality (AR) piloting visors and smart-helmet telemetry.

What We Offer

• Opportunity to work on bleeding-edge technology that directly protects tactical aviators.
• Highly competitive salary and comprehensive benefits package.
• State-of-the-art prototyping lab and testing facilities.
• Collaborative, mission-driven team culture.