Sr. Design Engineer

ALTEN Technology USA; San Jose (CA); On-site; USD 135,000 - 170,000; Full time

Job summary

A global engineering firm is seeking a Sr. Design Engineer (Thrust Integration) in San Jose, CA. You will be responsible for thrust unit design, CAD documentation, and system integration. The ideal candidate has 4+ years of experience in mechanical design, especially in aerospace or automotive systems, and strong skills in CAD modeling and structural analysis. This position offers a salary range of $135K-$170K based on qualifications and experience.

Qualifications

• Minimum of 4+ years of mechanical design experience in aerospace or automotive systems.
• Experience with propulsion system integration or similar rotating machinery applications.
• Proven ability to coordinate cross-functional technical initiatives.

Responsibilities

• Design and maintain CAD and drawings for thrust unit subsystems.
• Own thrust unit configuration management, tracking variations.
• Perform structural and thermal analysis using FEA tools.

Skills

Mechanical design experience

System-level integration

Proficiency in CAD modeling

Structural analysis

Communication skills

Education

Bachelor's Degree in mechanical/aerospace engineering

Tools

CAD software (NX preferred)

FEA software (ANSYS, NASTRAN preferred)

Job description

Sr. Design Engineer (Thrust Integration)

San Jose, CA

We’re ALTEN Technology USA, an engineering company helping clients bring groundbreaking ideas to life—from advancing space exploration and life-saving medical devices to building autonomous electric vehicles.

As part of the global ALTEN Group—57,000+ engineers in 30 countries—we deliver across the entire product development cycle, from consulting to full project outsourcing.

When you join ALTEN Technology USA, you’ll collaborate on some of the world’s toughest engineering challenges, supported by mentorship, career growth opportunities, and comprehensive benefits.

As Sr. Design Engineer (Thrust Integration) you will be responsible for:

• Design and Engineering
• Develop and maintain CAD and drawings to document interfaces between thrust unit subsystems and airframe interfaces
• Own and maintain thrust unit envelope CAD models and keep out zones to enable comprehensive vehicle package studies
• Own thrust unit configuration management, tracking various pedigrees and versions of hardware
• Lead detailed design and development of the thrust unit attach hardware from concept through production
• Assist in fairing integration design to optimize aerodynamic and thermal performance and system accessibility
• Interface with maintenance team to ensure thrust unit designs meet serviceability goals and enable efficient maintenance operations
• Collaborate with manufacturing team to ensure seamless aircraft integration processes, optimize assembly tooling design, and develop suitable shipping and handling solutions
• Analysis and Project Management
• Own and maintain comprehensive mass budget tracking for all thrust unit subsystems, identifying risks and weight optimization opportunities
• Perform structural and thermal analysis of thrust unit components using FEA tools
• Conduct trade studies to optimize system integration, mass efficiency, and performance
• Support test planning and validation activities for thrust unit assemblies
• Analyze test data and implement design improvements based on findings
• Leadership and Collaboration
• Collaborate with vehicle integration, airframe, aerodynamics, loads, and systems teams to ensure integrated thrust unit meets all requirements
• Work cross-functionally with sourcing and quality teams to support supplier selection, component qualification, and inspection requirements for integration components
• Participate in design reviews and provide technical expertise for critical integration decisions

Qualifications:

• Education & Experience
• Bachelor's Degree in mechanical/aerospace engineering, or related field
• Minimum of 4+ years of mechanical design experience, preferably in aerospace or automotive systems
• Proven experience with system-level integration, interface management, and mount design
• Experience with propulsion system integration or similar rotating machinery applications
• Experience generating Bills of Materials (BOM) and managing change control processes
• Technical Expertise
• Proficiency in CAD modeling (NX preferred), 2D drawings, tolerance analysis, and GD&T
• Strong understanding of structural analysis and FEA software packages (ANSYS, NASTRAN preferred)
• Knowledge of aerospace fastening methods, mounting systems, and structural interfaces
• Experience with mass budgeting, configuration management, and systems integration
• Understanding of manufacturing processes for aerospace structural components
• Communication and Organization
• Proven ability to coordinate cross-functional technical initiatives across multiple subsystem teams
• Excellent documentation and communication skills for maintaining complex interface requirements
• Capacity to manage multiple integration challenges and priorities simultaneously
• Strong analytical and problem-solving skills for resolving interface conflicts
• Additional Requirements
• Availability for domestic travel as needed
• Demonstrated commitment to safety and quality in engineering practices

Preferred Qualifications:

• Aerospace development and certification experience
• Experience with electric propulsion systems or hybrid powertrains
• Background in aircraft structural design and certification requirements
• Self-motivated with exceptional attention to detail and systems-thinking approach
• Track record of successful product integration and launch experience
• Experience with vibration isolation and dynamic system mounting

Salary Range: $135K-$170K

The actual salary offered is dependent on various factors including, but not limited to, location, the candidate’s combination of job-related knowledge, qualifications, skills, education, training, and experience

ALTEN Technology is an Equal Opportunity Employer. Our Policy is to extend opportunities to qualified applicants and employees on an equal basis regardless of an individual’s age, race, color, sex, religion, national origin, disability, sexual orientation, gender identity/expression or veteran status.

ALTEN Technology is a federal contractor subject to the requirements of the Vietnam Era Veterans’ Readjustment Assistance Act (VEVRAA) and Executive Order 11246. We are an Equal Opportunity Employer and consider all qualified applicants without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, disability, or veteran status.