Senior Mechanical Engineer - FEA & Thermal Design

Red Cat Holdings; Salt Lake City (UT); On-site; USD 110,000 - 165,000; Full time

Job summary

Red Cat Holdings is seeking a Senior Mechanical Engineer to lead the design, analysis, and development of complex mechanical systems from concept to production release. You will guide detailed mechanical design, perform advanced analyses, and ensure performance, reliability, and manufacturability.

Collaboration with Electrical, Software, Manufacturing, Quality, and Supply Chain is essential. The role requires hands-on design with deep analytical capability in structural FEA, vibration and modal

Qualifications

• 10+ years of mechanical engineering experience in design and analysis.
• BS or MS in Mechanical or Aerospace Engineering.
• Proven expertise in structural FEA, vibration, and heat transfer.
• Experience in injection-molded plastic components and high-volume production.
• Strong collaboration with cross-functional teams.

Responsibilities

• Own the mechanical design and detailed implementation from concept through sustaining.
• Develop and maintain mechanical architectures, layouts, and detailed component designs.
• Perform advanced structural analysis (FEA) to validate strength, stiffness, fatigue, and durability requirements.
• Conduct vibration and modal analysis to evaluate dynamic response, resonance, and environmental loading.
• Perform thermal and heat transfer analysis to ensure safe and reliable operation.
• Translate high-level product requirements into clear, traceable mechanical requirements and design solutions.
• Lead design trade studies to down-select materials, architectures, and manufacturing processes.
• Design for injection molding, including part geometry, draft, gating considerations, tolerances, and material selection.
• Apply DFM/DFA and DFT best practices to optimize cost, quality, and manufacturability.
• Create and maintain accurate CAD models, drawings, and GD&T using SolidWorks or equivalent CAD tools.
• Support prototype builds, testing, and design iteration based on verification and validation results.
• Collaborate with suppliers and contract manufacturers to review designs, tooling, and production readiness.
• Support root-cause analysis and corrective actions for test, quality, or manufacturing issues.
• Mentor junior engineers and provide technical guidance on best design and analysis practices.
• Maintain mechanical documentation and bills of materials (BOMs) within the PLM system throughout the product lifecycle.

Skills

Structural FEA

Vibration analysis

Modal analysis

Heat transfer

Injection molding design

SolidWorks

Education

BS or MS in Mechanical or Aerospace Engineering

Tools

PDM

PLM systems

Job description

Red Cat Holdings is seeking a Senior Mechanical Engineer to lead the design, analysis, and development of complex mechanical systems from concept to production release. You will guide detailed mechanical design, perform advanced analyses, and ensure performance, reliability, and manufacturability.

Collaboration with Electrical, Software, Manufacturing, Quality, and Supply Chain is essential. The role requires hands-on design with deep analytical capability in structural FEA, vibration and modal