Senior Mechanical Design Engineer - Aviation
fairway importexportCarson City (NV)
Senior Mechanical Design Engineer - Aviation
Posted 5 days ago
fairway importexportCarson City (NV)
SENIORITY
Senior
About the role
Job DescriptionSUMMARY: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 Responsibilities1. 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 & DFMConduct 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.
Before you apply
Applying takes about a minute. These four things decide how fast it moves after that.
Your profile is current
It's what we read first. Occupations, seniority and locations matter more than a long history.
Two examples you can talk through
Not a portfolio — just two pieces of work where you can explain the decisions and what you'd change.
A number in mind
What you're on now and what would make you move. We negotiate better when we know both.
Your notice period
Employers plan around it, and it's the question that stalls offers most often.
Once you apply, someone reads it and calls you before anything reaches the employer — usually within two working days.