Sr. Mechanical Systems Engineer / Technical Lead

Aurex; Huntsville (AL); On-site; USD 145,000 - 165,000; Full time

Job summary

Aurex seeks a Sr. Mechanical Systems Engineer / Technical Lead in Huntsville to design, develop, and deliver aerospace hardware. You will blend hands-on CAD work with leadership, coordinating with suppliers and customers to meet requirements from concept through fabrication and testing.

The role emphasizes leading hardware programs, optimizing interfaces, tolerances, and manufacturing considerations, while maintaining rigorous documentation and engineering plans for multi-program delivery.

Qualifications

• Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, or related STEM.
• 10+ years in mechanical design or hardware development.
• Experience leading hardware projects and coordinating with suppliers.
• Proficiency with 3D CAD and detailed drawings (SolidWorks).

Responsibilities

• Develop mechanical concepts, CAD models, drawings, and assemblies.
• Translate requirements into defined interfaces, tolerances and acceptance criteria.
• Evaluate designs for manufacturability, assembly, reliability, and cost.
• Lead technical execution and coordinate with customers and suppliers.
• Prepare test procedures and review acceptance criteria.

Skills

Mechanical design experience

CAD modeling (SolidWorks)

Tolerance analysis (GD&T)

Manufacturing process knowledge

Leadership of technical discussions

Customer & supplier coordination

Engineering documentation

Education

Bachelor’s degree in Mechanical Engineering or Aerospace Engineering

Tools

Altium Designer

Job description

Who We Are

Aurex is a mission-focused aerospace and defense company building the next frontier of deterrence. From hypersonics and missile defense to hardened networks and orbital systems, we design, test, and deliver the platforms that turn unproven ideas into battlefield-ready capability. Born in Huntsville and built for speed, Aurex brings together aerospace veterans, combat-tested operators, and forward-leaning technologists to solve problems that matter—fast. We move from whiteboard to warfighter with precision, clarity, and zero tolerance for fluff.

Location

Huntsville, AL

Job Summary

Aurex is seeking a Sr. Mechanical Systems Engineer / Technical Lead to design, develop, and deliver aerospace and defense hardware across multiple programs. This role combines hands‑on mechanical design with technical leadership, supplier coordination, and responsibility for moving engineering work from customer requirements through fabrication, integration, and acceptance. You will support work ranging from launch‑vehicle and payload structures to complex fabricated assemblies and electronic equipment enclosures. You will develop and review CAD models and drawings, resolve manufacturing and interface issues, and work directly with customers and suppliers to establish achievable technical requirements. The ideal candidate has taken hardware from concept through fabrication and test, understands how design decisions affect cost and schedule, and can lead technical execution while contributing directly to the engineering work.

Key Responsibilities

Mechanical Design & Development

• Develop mechanical concepts, CAD models, detailed drawings, and assembly documentation for aerospace and defense hardware.
• Translate customer requirements into designs with defined interfaces, materials, tolerances, and acceptance requirements.
• Evaluate designs for manufacturability, assembly, inspection, reliability, and cost.
• Work with structural analysts and other specialists to resolve design issues and incorporate analysis findings.
• Support equipment packaging and mechanical integration of electronic hardware.

Manufacturing & Supplier Coordination

• Assemble complete technical work packages for supplier quoting and fabrication.
• Review customer drawings and specifications to identify impractical tolerances, incomplete requirements, and manufacturing risks before work is committed.
• Work with customers and suppliers to resolve technical discrepancies and agree on achievable requirements.
• Support supplier selection, technical quote evaluations, fabrication reviews, and source inspection.
• Resolve manufacturing nonconformances and proposed substitutions through the appropriate engineering and quality processes.

Technical Leadership & Project Execution

• Serve as the technical lead for assigned hardware efforts, coordinating engineering tasks, interfaces, and deliverables.
• Develop and maintain engineering plans, estimates, schedules, and technical risk assessments.
• Coordinate with program management, Contracts, Quality, and suppliers to keep technical execution aligned with authorized scope.
• Identify changes affecting cost, schedule, or performance and communicate their impact before additional commitments are made.
• Support technical proposals, feasibility studies, and customer discussions across business units.

Integration, Testing & Documentation

• Support prototype assembly, hardware integration, troubleshooting, and verification testing.
• Develop and review test procedures and acceptance criteria with the responsible engineering and quality teams.
• Maintain configuration-controlled models, drawings, bills of material, and engineering change records.
• Prepare clear technical reports, review materials, and customer status updates.
• Capture design and manufacturing lessons for use on subsequent programs.

Basic Qualifications

• Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, or a closely related STEM discipline.
• 10+ years of professional experience in mechanical design, hardware development, or systems integration.
• Proficiency with SolidWorks or comparable 3D CAD software, including detailed drawings and assembly models.
• Experience applying geometric dimensioning and tolerancing and evaluating tolerance stack-ups.
• Practical knowledge of machining, welding, fabrication, materials, and assembly processes.
• Experience preparing engineering drawing packages and resolving technical questions with manufacturing suppliers.
• Experience supporting hardware through design reviews, fabrication, integration, and testing.
• Ability to lead technical discussions with customers, suppliers, and multidisciplinary engineering teams.
• Strong analytical, troubleshooting, documentation, and communication skills.

Preferred Qualifications

• Experience with launch vehicles, spacecraft hardware, payload adapters, propulsion hardware, or ground support equipment.
• Experience with large fabricated structures, precision machined components, and welded assemblies.
• Experience supporting structural analysis and translating analysis results into practical design changes.
• Familiarity with electronic packaging, PCB mechanical interfaces, connectors, cable routing, and enclosure design.
• Experience with Altium Designer or similar electronics design tools.
• Experience managing engineering projects, supplier schedules, technical risks, and customer deliverables.
• Experience developing technical proposals, statements of work, estimates, and development plans.
• Familiarity with aerospace quality systems, configuration management, and source‑inspection activities.

How You Will Be Rewarded

The salary for this role is $145,000–$165,000 per year. We offer a comprehensive total rewards approach to compensation, providing incentives and benefits that extend far beyond the base salary. Compensation is determined by the candidate’s work experience, education, training, and relevant skills. We offer a competitive benefits package designed to support our employees’ health, well‑being, and professional growth.

The posted salary range represents Aurex’s good‑faith estimate of the anticipated hiring range for this position. The specific salary offered within this range will be determined based on the candidate’s relevant experience, education, training, and job‑related qualifications.

Aurex is an Equal Opportunity Employer. It prohibits discrimination, retaliation, or any type of harassment on the basis of race, color, religion, gender, gender identity or expression, sexual orientation, national origin, genetics, disability, age, veteran status, citizenship, immigration status, or any other legally protected status in employment, including in hiring, firing, and recruiting decisions. All applicants must be authorized to work lawfully in the United States for positions at Aurex. There may be limited circumstances in which a law, regulation, executive order, or government contract would require certain citizenship; only in those limited circumstances would Aurex require certain citizenship status to comply with the relevant law, regulation, executive order, or government contract applicable to that position. For all other positions, Aurex does not consider an applicant’s citizenship but only requires that the applicant be authorized to work lawfully in the United States. If a position is one that falls under export control laws and regulations requiring authorization from the U.S. government to access export‑controlled items, any hiring is contingent on the applicant passing the export compliance assessment, which is separate from the I‑9 process, for that specific position. A background check will be required prior to any hire.

Elevate your career by joining the Aurex Platform, a leader in aerospace innovation!