Mechanical Design & FEA Engineer – Aerospace Motion Systems

Our client, a leader in aerospace and flight simulation, is seeking an experienced Mechanical Design & Analysis Engineer to join their engineering team onsite in Southampton, PA.

You’ll work on multi-axis motion platforms — fully custom cockpits and simulators that replicate real-world aircraft dynamics. Each system is uniquely engineered, presenting a distinct technical challenge with every project. This role blends mechanical design with structural and motion analysis, giving you the opportunity to optimize large, complex assemblies, validate performance with FEA, and support prototyping and testing.

You’ll collaborate across engineering functions, fabrication teams, and vendors to ensure assemblies perform as intended. You’ll work across a broad range of subsystems — from structural frames and gearboxes to actuators and electromechanical drives — so every day brings a new challenge. You’ll contribute to both new designs and continuous improvements across mechanical systems.

This position is ideal for engineers who enjoy dynamic mechanisms, motion systems, or mechatronics, with hands-on problem solving and the chance to make a direct impact on advanced aerospace platforms.

Key Responsibilities

• Design and develop large-scale mechanical assemblies for motion-enabled cockpits and aerospace simulation platforms
• Engineer multi-axis motion systems, including planetary gearboxes, DC/AC drives, couplings, and supporting structural frames
• Perform mechanical analysis and FEA (ANSYS, Abaqus, NASTRAN, or similar) to verify structural integrity, motion fidelity, and component performance
• Interpret test data and correlate results with simulations to ensure real-world performance
• Optimize designs for weight, stiffness, durability, and manufacturability
• Break complex assemblies into manufacturable subassemblies for internal fabrication and vendor production
• Integrate commercial off-the-shelf (COTS) components with custom-designed mechanisms
• Develop pneumatic actuation systems and integrate electromechanical components for precise motion control
• Collaborate with fabrication teams, vendors, and cross-functional engineers to resolve design, assembly, and testing challenges
• Document technical findings, design updates, and analysis results for internal teams and regulatory compliance
• Support prototyping, testing, and continuous improvement initiatives

Requirements

• 5 years of experience in mechanical design and FEA analysis of complex systems (aerospace, defense, robotics, industrial machinery, or motion platforms)
• Hands-on experience with FEA tools such as ANSYS, Abaqus, NASTRAN, or similar
• Proven experience designing motion systems, multi-axis mechanisms, gearboxes, pneumatic actuation, and electromechanical drives
• Proficiency in CAD tools, Autodesk Inventor preferred
• Strong understanding of structural weldments, sheet metal design, GD&T, and manufacturability considerations
• Ability to troubleshoot mechanical issues, recommend improvements, and correlate analysis with physical testing
• Excellent communication skills with experience collaborating across fabrication teams, vendors, and cross-functional engineering groups
• US Citizen or lawful US Resident

Location: Southampton, PA

Onsite: Monday-Friday

Benefits: Medical, Dental, Vision, 401(k) with match, PTO, Life and AD&D, Short- and Long-Term Disability, annual performance review, continuing education, and professional development opportunities.

This role is designed for long-term growth, with a clear path toward senior mechanical engineering responsibilities as experience develops.

If this aligns with your experience, please apply and one of our recruiters will be in touch.

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