Design Engineer

POSITION SUMMARY:

Pacific Aero Tech (PAT) is an FAA Part 145 Repair Station specializing in aerospace transparencies and advanced repair development. The Design Engineer is fully accountable for reverse engineering components and creating manufacturable definition, leading, and delivering FAA-approved DER qualification tests for new and existing aircraft window repairs, and developing efficient production systems capable of scaling.

This engineer will own component designs, drive R&D experimentation, author deliverable qualification reports and test results, and deliver compliant engineering data packages that enable PAT to efficiently scale new programs.

This role requires strong initiative and autonomy, familiarity with a controlled production environment, regulatory understanding and fluency, hands-on experimentation capability, and the ability to work in a cross functional team to drive development program milestones.

ESSENTIAL DUTIES AND RESPONSIBILITIES:

1. Reverse Engineering

• Be able to measure and understand how to best define a component’s functional features.
• Ensure engineering data meets 14 CFR, FAA guidance, airworthiness, and safety requirements for Part 145 repairs.
• Understand Design for manufacture and apply GD&T per ASME Y14.5 to all critical features and interfaces.
• Understand metrology and be familiar with the approaches to gathering part definition data and variance.
• Be able to use the advanced features of SolidWorks to adequately define models and drawings.

2. Research, Experimentation & Technical Development

• Design and execute R&D experiments to validate new repair methods, materials, tooling, and processes.
• Build and test prototype parts, assemblies, and fixtures; analyze results and iterate designs.
• Develop and validate process parameters (thermal, mechanical, material, electrical as applicable).
• Translate experimental outcomes into repeatable, production-ready engineering solutions.
• Understand Manufacturing processes and tooling design/development.

3. Develop Test Plans for certification

• Maintain audit-ready documentation and traceability throughout the program lifecycle.
• Serve as the technical focal point between FAA, suppliers, and internal stakeholders.
• Produce engineering drawings, models, and data packages using SolidWorks.
• Define specifications, acceptance criteria, and standards for repair processes and tooling.
• Support or author engineering substantiation, including test reports, analysis, and compliance narratives.

4. FAA Part 145 Integration & Production Enablement

• Convert approved DER data into shop-floor-ready work instructions, inspection criteria, and training materials.
• Support production during initial implementation and ramp-up of new repair products.
• Troubleshoot technical issues in manufacturing and drive corrective engineering actions.
• Ensure new designs are robust, repeatable, auditable, and cost-effective, and scalable.

QUALIFICATIONS:

Required

• Bachelor’s degree in Mechanical, Materials, Aerospace, or Electrical Engineering (ABET-accredited).
• 2 years of hands-on engineering experience in a regulated industry (Aerospace, Medical, etc.), preferably in Part 145 or Part 21 environments.
• Demonstrated direct experience with R&D and certification-driven engineering projects.
• Strong proficiency in SolidWorks and engineering documentation.
• Proven ability to design experiments, analyze results, and defend technical conclusions.
• Comfortable working in manufacturing, lab, and shop environments.
• Strong understanding of metrology and reverse engineering
• Strong Technical Writing skills.
• Tooling Design
• Experience dealing directly with vendors/suppliers to procure and initiate testing/engineered components/tools.

Preferred

• Working knowledge of FAA regulations, DER processes, and conformity expectations.
• Experience with aerospace transparencies, bonded structures, or complex assemblies.
• Prior responsibility for authoring or defending substantiation data.
• Experience translating R&D outcomes into certified, production-released repairs.
• Composite Experience
• Electrical Design Experience
• Qualification testing Experience

PHYSICAL AND WORK REQUIREMENTS

• Combination of office, laboratory, and manufacturing environments.
• Regular hands-on work with tools, fixtures, prototype hardware, and test setups.
• Ability to lift up to 40 lbs and work around chemicals, heat, and production equipment.
• Compliance with all PAT safety, quality, and FAA regulatory requirements.

Pacific Aero Tech provides reasonable accommodations to qualified individuals with disabilities in accordance with the Americans with Disabilities Act (ADA) and Washington State Law Against Discrimination (WLAD – RCW 49.60).
Employees who need accommodation to perform essential job functions are encouraged to notify Human Resources.

Equal Employment Opportunity (EEO)

Pacific Aero Tech is an Equal Opportunity Employer. Employment decisions are made without regard to race, color, national origin, sex, pregnancy, sexual orientation, gender identity, marital status, ancestry, veteran or military status, disability, genetic information, age, or any other protected status under federal law (Title VII, ADA, ADEA) or Washington State law (RCW 49.60).

Harassment-Free Workplace Statement

The Company prohibits unlawful harassment, discrimination, and retaliation in accordance with Title VII, EEOC regulations, and Washington State Human Rights Commission (WSHRC) standards.

Washington Pay Transparency Compliance (RCW 49.58)

In accordance with Washington State’s Equal Pay & Opportunities Act, salary ranges and benefit information will be provided in job postings for this role.

At-Will Employment

Employment with Pacific Aero Tech is at-will, consistent with Washington State employment law, and may be terminated by either the employee or the Company at any time for any lawful reason.

Drug-Free Workplace

Pacific Aero Tech maintains a drug-free work environment consistent with federal safety-sensitive regulations and Washington State law.

Job Type: Full-time

Pay: $85,000.00 - $115,000.00 per year

Benefits:

• 401(k)
• 401(k) matching
• Dental insurance
• Flexible spending account
• Health insurance
• Health savings account
• Life insurance
• Paid time off
• Tuition reimbursement
• Vision insurance

Application Question(s):

• Will you now or in the future require employment visa sponsorship?

Work Location: In person

Salary : $85,000 - $115,000