Sr. Mechanical Engineer, DFM Focus

JOB TITLE: Sr. Mechanical Engineer
LOCATION: Irvine CA
SALARY: $130K 190K/year

We are a national aerospace and defense staffing agency seeking highly qualified candidates for a position with a top-tier client.

Job Details:

• Job Type: Direct Hire

• Industry: Aerospace / Defense / Aviation

• Benefits: Medical dental and vision (Cigna)

• Perks: Bonus potential Priority access via Tier 1 supplier

• Openings Nationwide: Thousands of opportunities across the U.S.

Qualifying Questions:

• Are you a U.S. Person (U.S. citizen lawful permanent resident or protected individual) as defined under ITAR regulations

• Do you meet the educational and experience requirements for this role

• Can you commute to the job location or relocate if necessary

Summary:

• Leads mechanical design of airframe structures housings and complex assemblies for high-volume production.

• Applies DFM and DFA principles from concept through release to ensure cost quality and repeatability targets.

• Selects appropriate manufacturing processes including injection molding stamping die casting compression molding and machining.

• Collaborates with electrical engineering teams to integrate batteries motors avionics sensors and wiring within constrained spaces.

• Partners with aerodynamics teams to meet surface quality requirements including roughness gaps and alignment.

• Performs tolerance analyses material selection and manufacturability trade-off evaluations.

• Works with manufacturing engineers suppliers and production teams to validate tooling and resolve build issues.

• Creates and maintains detailed CAD models assemblies and production documentation under configuration control.

• Supports prototype builds and provides hands-on troubleshooting during integration and testing.

• Mentors junior engineers and promotes best practices in high-volume mechanical design.

Requirements:

• Must be a U.S. Person (as defined by ITAR).

• 7 years of experience in mechanical design in aerospace automotive consumer electronics robotics or similar fields.

• Proven experience designing for high-volume production at rates of 1000 units per month.

• Strong understanding of DFM DFA tooling and manufacturing cost drivers.

• Proficiency in 3D CAD tools with SolidWorks preferred.

• Experience working with electrical integration including harnessing PCB packaging and component integration.

• Familiarity with high-volume manufacturing processes such as injection molding sheet metal stamping die casting extrusion or composites.

• Strong knowledge of tolerance stack-ups materials and mechanical fundamentals.

• Bachelors degree in Mechanical Engineering Aerospace Engineering or related field from an accredited institution.

• Preferred: Experience with injection-molded stamped die-cast extruded or composite components and scaling products from prototype through production ramp.

About Us:

The Structures Company is a premier national aerospace and defense staffing agency specializing in contract contract-to-hire and direct hire placements. We deliver expert workforce solutions across engineering IT production maintenance and support roles.

As trusted partners to leading aerospace and defense OEMs and Tier 1 suppliers we connect professionals with career opportunities to grow and excel in aviation aerospace and defense.

Eligibility Requirements:

Must be a U.S. Person (U.S. citizen lawful permanent resident or protected individual under 8 U.S.C. 1324b(a)(3)) to comply with ITAR regulations.

Keywords: aerospace aviation engineering maintenance aircraft design defense

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