Sr. Mechanical Engineer

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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