Mechanical Engineer

Allocor Tech; Crozet (VA); On-site; USD 90,000 - 130,000; Full time

Benefits offered by this job

Medical insurance

Dental and vision coverage

401(k) with company match

Paid time off (unlimited)

HSA plan

Job summary

Allocor.tech in the United States is seeking a Mid-Level Mechanical Engineer to own detailed mechanical design for high‑reliability avionics and power electronics subsystems, focusing on enclosures, thermal management, and structural interfaces for hardware already flying on customer UAS and other unmanned platforms.

You will design, analyze, document, and support bring‑up of mechanical solutions while helping strengthen design standards and processes as Allocor.tech scales.

Qualifications

• Bachelor’s degree in Mechanical Engineering (MS a plus).
• 3–6 years of mechanical design engineering experience focused on electronic enclosures, thermal management, or electromechanical systems.
• Strong proficiency in SolidWorks (parts, assemblies, drawings) and SolidWorks PDM.
• Demonstrated experience performing structural and/or thermal FEA (SolidWorks Simulation, ANSYS, or equivalent).
• Solid GD&T per ASME Y14.5 and mechanical drawing standards.

Responsibilities

• Design mechanical solutions for enclosures, thermal management systems, and structural mounts using SolidWorks and SolidWorks PDM.
• Perform structural and thermal FEA to validate heat rejection, vibration response, structural integrity, and environmental performance for high-power avionics hardware.
• Create complete technical data packages (TDPs) with revision control and release processes.
• Collaborate with electrical engineering on packaging, connector placement, thermal interface materials, and integration of power electronics assemblies.
• Support prototype fabrication, first-article inspection, GD&T definition, and vendor communication to ensure manufacturability.
• Participate in mechanical design reviews (PDR, CDR), presenting analysis results, trade studies, and risk assessments.
• Contribute to design standard improvements, simulation practices, GD&T application, and documentation.
• Work across Engineering, Operations, and external suppliers to meet aggressive timelines.

Skills

Attention to detail

Cross-functional collaboration

Analytical thinking

Education

Bachelor’s degree in Mechanical Engineering

MS a plus

Tools

SolidWorks

SolidWorks PDM

SolidWorks Simulation/FEA

ANSYS

Job description

Join a fast-scaling aerospace startup and set the standard for mechanical engineering excellence.

Company Overview

Allocor.tech designs and manufactures mission-critical power electronics and avionics including motor controllers, battery management systems, power distribution, flight control, and flight termination systems for unmanned aerial vehicles (UAS/UAM) and unmanned maritime platforms. Our customers are leaders in advanced air mobility, uncrewed aircraft, and electric watercraft. The team brings deep experience from organizations including Northrop Grumman, L3Harris, Sierra Space, and Aurora Flight Sciences.

We are a team of approximately 35 people generating roughly $10M in annual revenue. We recently closed a $6.0M Series A and are projecting 100–200% revenue growth over the next year as we scale production, expand our customer base, and professionalize the business beyond its engineering-led roots. This is a pivotal moment: we are building the technical depth and process rigor required to support rapid, disciplined growth while protecting the speed and agility that got us here.

Role Summary

The Mid-Level Mechanical Engineer will own detailed mechanical design work for high-reliability avionics and power electronics subsystems, with a focus on enclosures, thermal management, and structural interfaces for hardware that is already flying on customer UAS, eVTOL, and unmanned platforms. This is a hands-on role for an engineer who thrives in a fast-moving environment and wants real ownership of designs that reach flight hardware. You will design, analyze, document, and support bring-up of mechanical solutions while helping strengthen the standards and processes that will scale with Allocor.tech.

Key Responsibilities

Mechanical Design & Analysis

• Design mechanical solutions for enclosures, thermal management systems, and structural mounts using SolidWorks and SolidWorks PDM.
• Perform structural and thermal FEA to validate heat rejection, vibration response, structural integrity, and environmental performance for high-power avionics hardware.
• Create complete technical data packages (TDPs) that meet AS9100 expectations, including proper revision control and release processes.
• Collaborate closely with electrical engineering on packaging, connector placement, thermal interface materials, and integration of power electronics assemblies.

Prototyping, Documentation & Collaboration

• Support prototype fabrication, first-article inspection, GD&T definition, and vendor communication to ensure designs are manufacturable and meet requirements.
• Participate in mechanical design reviews (PDR, CDR), presenting analysis results, trade studies, and risk assessments to cross-functional stakeholders.
• Contribute to the continuous improvement of design standards, simulation practices, GD&T application, and configuration-controlled documentation.
• Work effectively across Engineering, Operations, and external suppliers to keep programs on aggressive timelines.

Qualifications

Required

• Bachelor’s degree in Mechanical Engineering or equivalent (MS a plus).
• 3–6 years of mechanical design engineering experience focused on electronic enclosures, thermal management, or electromechanical systems.
• Strong proficiency in SolidWorks (parts, assemblies, drawings) and SolidWorks PDM (or equivalent PLM/configuration management system).
• Demonstrated experience performing structural and/or thermal FEA (SolidWorks Simulation, ANSYS, or equivalent).
• Solid command of GD&T per ASME Y14.5 and mechanical drawing standards.
• Experience creating and managing technical data packages in a configuration-controlled environment.

Preferred

• Experience designing for aerospace or defense applications with DO-160 or MIL-STD environmental qualification requirements.
• Familiarity with AS9100 design control, document release processes, and quality management expectations.
• Hands-on DFM/DFA experience with sheet metal, CNC machining, and injection molding.
• Prior work supporting power electronics, avionics, or high-reliability flight hardware.

Key Attributes

• Hands-on engineer who takes ownership of designs from concept through documentation and prototype support.
• Comfortable working in a small, agile team with short decision cycles and real customer hardware.
• Detail-oriented with high standards for analysis, documentation, and design rigor.
• Collaborative partner who communicates clearly with electrical, manufacturing, and leadership stakeholders.
• Excited by the opportunity to help strengthen mechanical engineering processes as the company scales.

What Success Looks Like in the First Year

• You own key mechanical design packages (enclosures, thermal solutions, mounts) that progress cleanly through design reviews and into prototype hardware.
• Technical data packages and drawings are consistently clear, complete, and configuration-controlled.
• FEA and analysis work effectively de-risks designs and supports timely decisions.
• Collaboration with electrical engineering on packaging and thermal integration is smooth and proactive.
• You contribute to stronger design standards and documentation practices that benefit the broader mechanical team.
• Your work directly supports flight hardware deliverables on customer programs and Allocor.tech’s growth trajectory.

This position may require prolonged periods of sitting, standing, walking, computer work, and occasional exposure to moderate levels of noise, dust, and fumes in production areas.

Level and base salary will be determined on a case-by-case basis and may vary based on the following considerations: job-related knowledge and skills, education, and experience. Base salary is just one component of our total rewards package. Employees may receive equity opportunities and/or cash bonus, and have access to a robust benefits package including: top tier medical HMO, PPO & a 100% company-sponsored HSA plan option, dental and vision coverage, unlimited PTO, 11 paid holidays per year, flexible spending and dependent care savings accounts, paid parental leave, disability insurance, life insurance, and access to a 401(k) retirement plan with company match. Eligibility for benefits may vary based on employment status; please check with your recruiter for a comprehensive list of the benefits available for this role. Benefit programs are subject to change at the company’s discretion.

Important Information

FOR CANDIDATES SEEKING TO WORK IN US OFFICES ONLY:

To conform to U.S. Government technology export regulations, including the International Traffic in Arms Regulations (ITAR), Allocor.Tech Employees must be a U.S. citizen, lawful U.S. permanent resident (i.e., current Green Card holder), or lawfully admitted into the U.S. as a refugee or granted asylum, or be eligible to obtain the required authorizations from the U.S. Department of State and/or the U.S. Department of Commerce, as applicable.

Allocor.tech provides equal employment opportunities to all employees and applicants for employment and prohibits discrimination and harassment of any type without regard to race, color, religion, age, sex, national origin, disability status, genetics, protected veteran status, sexual orientation, gender identity or expression, or any other characteristic protected by federal, state, or local laws. This policy applies to all terms and conditions of employment at Allocor.Tech, including recruiting, hiring, placement, promotion, termination, layoff, recall, transfer, leaves of absence, compensation, and training.