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 1,000+ 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.
Bachelor’s 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
Take your career to new heights—apply today!
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