Senior Mechanical Engineer - Machine Design

Beyond New Horizons; Tullahoma (TN); On-site; USD 139,000 - 185,000; Full time

Benefits offered by this job

Competitive salaries

Continuing education assistance

Healthcare benefits packages

401K with employer matching

PTO with holiday schedule

Job summary

Beyond New Horizons, LLC is seeking a Senior Mechanical Design Engineer to lead machine design activities for USAF Test Operations at Arnold AFB, TN. You will perform complex analysis, guide design reviews, and mentor junior engineers while coordinating with cross-functional teams.

The role requires a BS in mechanical engineering, 10+ years in machine design and FEA with GD&T; U.S. citizenship and ability to obtain a DoD clearance are mandatory.

Qualifications

• Bachelor's degree in mechanical engineering or equivalent.
• Minimum 10 years' experience in machine and mechanism design.
• 10 years' experience in FEA and GD&T (ASME Y14.5).
• Active security clearance and US citizenship are required.

Responsibilities

• Independently perform complex analysis and design of components, systems, and facilities.
• Check designs and analyses from less experienced engineers.
• Develop concepts for new hardware and perform supporting analyses.
• Design one-of-a-kind mechanisms, wind tunnel models, and test fixtures.
• Provide engineering support to craft workforce for maintenance and upgrades.
• Produce complete design packages with drawings, analyses, and specs.
• Lead multi-year projects as required and coach junior engineers.
• Adhere to PPE policy and safety requirements.

Skills

Machine design

Finite element analysis (FEA)

ASME Y14.5 GD&T

Team leadership

Stress analysis

Education

Bachelor's degree in mechanical engineering

Tools

Autodesk Inventor

ANSYS Workbench

ABAQUS

NASTRAN

STAAD.Pro

Revit

Siemens NX

Job description

Job Title: Senior Mechanical Engineer - Machine Design

Location: Arnold AFB, TN

Job Family Code: O - Engineering

Function/Branch: Design & Manufacturing

Directorate: Engineering & Tech Support

Position Type: Regular, Full Time

Pay Type: Exempt

Grade: L10 (OA1015)

Salary Range or Starting Hourly Rate: L10: $139,000 - $185,000/ per year

Job Locations: US-TN-Arnold AFB

Requisition Number: 2026-25281

Category: Engineering

Overview

Beyond New Horizons, LLC (BNH) has an exciting opportunity for a Sr. Mechanical Design Engineer, supporting the United States Air Force Test Operations and Sustainment efforts at Arnold AFB in Manchester, TN. The Mechanical Engineer will be working as a member of an integrated team responsible for supporting the United States Air Force Test Operations and Sustainment efforts.

Open to internal and external candidates.

Job Summary

The successful candidate for Sr. Mechanical Design Engineer will leverage broad experience to provide Machine and Mechanism design. This Engineer will independently perform complex design and analysis tasks, lead medium to large sized teams in development of designs, check design packages, lead design reviews, and mentor/oversee early career engineers.

Job Duties

• Independently perform complex analysis and design of components, systems, and facilities by using the mechanical engineering skills of statics, dynamics, mechanics of materials, machine element design, and manufacturability.
• Check complex analysis and design originated by less experienced engineers.
• Develop concepts for new hardware and provide thermal, structural, flow, or any other required analysis to support the proposed design. Evaluate the analysis results for suitability relative to applicable codes and standards.
• Designing one-of-a-kind of mechanisms, wind tunnel models, and test fixtures including associated stress analysis.
• Provide engineering support to the appropriate craft workforce to facilitate maintenance and repair of existing systems. Evaluate existing hardware for safety, security and potential for improvement.
• Work with the design team (drafters, checkers, etc.) to produce complete design packages, including detailed drawings, analysis reports, and equipment specifications, and be capable of communicating the details of these design packages to the remaining project team (system engineers, test engineers, project managers, craft supervisors, etc.)
• Serve as responsible engineer/point of contact for the Design Engineering support to a complex, multi-year project.
• Coordinate with the appropriate system engineer, craft supervisor, and/or work planner to ensure that hardware is fabricated and installed in accordance with the approved design package.
• May serve as Team Lead (typically >5 members) conducting complex analysis and design of components, systems, and facilities.
• Serves as an expert on Design Engineering execution, providing coaching and guidance to the rest of the team.
• It is a condition of employment to wear company issued PPE (Personal Protective Equipment) in accordance with supervisory direction and company policy.
• Perform other related duties as required.

Basic Qualifications

• S. degree in mechanical engineering from an accredited college or university and a minimum of 10 years' experience with machine and mechanism design.
• Ten (10) years' experience in finite element analysis (FEA) and applications of ASME Y14.5 Geometric Dimensioning and Tolerancing (GD&T).
• Must be able to obtain and maintain an active security clearance and maintain authorized user access to the AEDC local area network.
• S. Citizenship is required due to federal government contract compliance requirements and the necessity to access secure federal databases and networks on Arnold Air Force Base

Preferred Qualification

• 10 years of experience with application of finite element analysis (FEA) (ANSYS Work Bench Finite Element Analysis).
• 10 years of experience utilizing CAD (AUTODESK INVENTOR).
• 5 years' experience in the application of ASME Y14.5 Geometric Dimensioning and Tolerancing (GD&T).
• 5 years' experience providing support to model/machine shop during fabrication, assembly, and
• Experience with FEM/structural software (such as ANSYS, ABAQUS, NASTRAN, or STAAD.Pro) and 3D modeling tools (Revit or Siemens NX).
• Experience with welding procedures, fabrication shop drawings, and Geometric Dimensioning and Tolerancing (GD&T).
• Familiarity with wind tunnel model design and fabrication.
• Familiarity with turbine and rocket test cells, wind tunnels, space chambers, and/or arc heater facilities; or other industry product test facilities is desirable.
• Professional Engineering Licensure
• Active DoD Secret security clearance

What We Offer

• Competitive salaries
• Continuing education assistance
• Multiple healthcare benefits packages
• 401K with employer matching
• Paid time off (PTO) along with a federally recognized holiday schedule

Who We Are

Beyond New Horizons (BNH) is a fully populated joint venture of Astrion and Fluor Federal Services, Inc. formed to provide unmatched Test Operations and Sustainment services for the Arnold Engineering Development Complex. We chose our name to serve as an enduring reminder of our commitment to AEDC's rich aerospace research and development legacy anchored in AEDC's Toward New Horizons founding study and the unprecedented opportunities to greatly expand AEDC's capabilities and capacity Beyond those existing today. Leveraging the capabilities of our parent companies, BNH specializes in testing and evaluation for military and space systems combined with proven capability in large-scale Government program management, integration, engineering, and construction services for specialized and technically advanced high-hazard facilities.

Join our Team!

U.S. Citizenship is required. At this time BNH will not sponsor any applicants for employment authorization or offer any immigration related support for this position (i.e. H1b, F1 OPT, F-1 STEM OPT, F-1 CPT, J-1, E-2, E-3, L-1, or other forms of work authorization that require immigration support from an employer).

L10: $139,000 - $185,000 / year at Arnold Air Force Base, TN.

BNH is an Equal Employment Opportunity/Affirmative Action Employer. We provide equal employment opportunities to all employees and applicants for employment and prohibit 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, including recruiting, hiring, placement, promotion, termination, layoff, recall, transfer, leaves of absence, compensation, and training.