Senior Mechanical Engineer – Aerospace Thermal & Packaging Lead

Insight Global; Petaluma (CA); On-site; USD 90,000 - 150,000; Full time

Job summary

Insight Global seeks a Mechanical Engineer III to design, analyze, and test components for high-altitude aerospace electrical machines and electronics packaging. You will lead or support the mechanical packaging development and coordinate subcontractors to meet stringent environmental requirements.

You will drive the creation of mechanical drawings, define tolerances, and develop test plans while applying MIL-STD standards and best practices in a fast-paced team environment.

Qualifications

• Minimum 5-8 years of relevant mechanical engineering experience, with 3+ years in production rotating electrical machines or aerospace packaging.
• Experience drafting requirements for mechanical subsystems per MIL-STD 961D or equivalent.
• Proficient with SolidWorks for modeling, ANSYS for structural/fatigue, and ANSYS Icepack for thermal analysis.
• Extensive experience designing electrical rotating machines and performing thermal management tradeoffs.
• Experience with bonding techniques suitable for extreme environments and with BOM/documentation management.
• Familiarity with manufacturing methodologies and creating product documents.

Responsibilities

• Lead or support the thermal, structural, dynamic, and fluid-flow analyses for electronics equipment.
• Lead testing and data collection in lab and field environments.
• Model mechanical devices and select appropriate materials.
• Perform stress, fatigue, and thermal analyses and select bonding materials.
• Develop mechanical drawings and specify tolerances; prepare assembly instructions.
• Create test plans/procedures to verify designs and supervise team activities.
• Handle complex issues requiring in-depth analysis and coordinate subcontractors when needed.
• Maintain product documentation and bill of materials; contribute to process improvements.

Skills

Mechanical engineering

Team leadership

Thermal management

Materials properties

Problem solving

Communication

Education

MS in Mechanical Engineering

ASME senior membership (desired)

Tools

SolidWorks

ANSYS

ANSYS Icepack

Bonding techniques

BOM management

Documentation

Job description

Insight Global seeks a Mechanical Engineer III to design, analyze, and test components for high-altitude aerospace electrical machines and electronics packaging. You will lead or support the mechanical packaging development and coordinate subcontractors to meet stringent environmental requirements.

You will drive the creation of mechanical drawings, define tolerances, and develop test plans while applying MIL-STD standards and best practices in a fast-paced team environment.