Staff Mechanical Engineer

esaero; San Luis Obispo (CA); On-site; USD 130,000 - 175,000; Full time

Benefits offered by this job

Health insurance

PTO 120 hours/year

Life insurance

Supplemental coverage options

HSA benefits

401(k) with company match

Paid holidays

Job summary

ESAero in San Luis Obispo, CA seeks a Staff Mechanical Engineer to design, analyze, and validate mechanical components for aerospace programs. You will produce 3D models, drawings, and documentation, perform structural/thermal analyses, and collaborate with internal teams, suppliers, and manufacturing to ensure design intent is met.

The role involves full product lifecycle from concept through prototype build and test, with mentoring of junior engineers and leadership in design reviews.

Qualifications

• 9+ years of mechanical design experience required.
• Expert in SolidWorks and SolidWorks PDM with GD&T.
• Experience with HyperWorks and full lifecycle product development.
• Hands-on with machine shops and prototype validation.
• Strong collaboration across multidisciplinary teams.
• Excellent writing and MS Office proficiency.

Responsibilities

• Create/modify 3-D models, drawings, assemblies and SOWs.
• Perform structural and thermal analyses of structures/systems.
• Lead development, test plans and validation activities.
• Design for manufacturability, assembly, and maintainability.
• Support and mentor junior engineers.
• Coordinate with internal and external teams and suppliers.

Skills

SolidWorks

SolidWorks PDM

GD&T

HyperWorks

System integration

Lifecycle product development

Machining collaboration

MS Office

Technical writing

Organizational skills

Education

Bachelor’s degree in engineering

Tools

SolidWorks

SolidWorks PDM

HyperWorks

Job description

Staff Mechanical Engineer

Job Summary:

The Staff Mechanical Engineer will play a key role in the design, development, and validation of mechanical components and systems for new aircraft programs. This position supports multi-disciplinary product development activities, including concept creation, detailed design, analysis, test planning, and integration. The Staff Mechanical Engineer will produce 3D models, drawings, and engineering documentation; perform structural and thermal analyses; and collaborate closely with internal teams, suppliers, and manufacturing to ensure successful execution of design intent. This role requires strong technical proficiency, solid organizational skills, and the ability to apply engineering judgment in a fast-paced, collaborative environment. This is a mid-level engineering position that offers the opportunity to contribute across the full product lifecycle—from requirements definition through prototype build and test.

Responsibilities and Duties:

• Create or modify 3-D models, detailed drawings, assemblies and installations, system requirements, interface/supplier control drawings, performance specifications, system checkout procedures and statements of work.
• Structural or thermal analysis of structures and systems.
• Support the creation ofsystem requirements, trade studies, sub-component and test plans.
• Optimize designs for manufacturability (DFM), assembly (DFA), and maintainability.
• Support the creation of engineering development work orders, build guides and travelers.
• Collaborate with machinists, technicians, and manufacturing engineers to iterate quickly.
• Support and/or lead the development, test, verification, and validation of mechanical systems.
• Coordinate with internal and external integrated product teams.
• Provide manufacturing, component test and ground/flight test support.
• Utilize PDM for revision and configuration control
• Create and participate in design reviews
• Provide mentorship and technical guidance to junior engineers
• Contribute to long-term strategic planning within the discipline

Required Qualifications and Skills:

• Bachelor’s degree in engineering.
• Minimum 9 years of mechanical design experience
• Expert with SolidWorks and SolidWorks PDM (or similar)
• Expert at detailing drawings to include appropriate use of GD&T
• Experience with HyperWorks (or similar)
• Proficient at system integration and collaboration with multidisciplinary teams.
• Experience with Full Lifecycle Product Development
• Hands-on experience working with machine shops, integrating prototype designs, and conducting validation tests.
• Advanced understanding of structures, mechanisms, system layout, and materials
• Proficiency with the Microsoft Office Suite (Word, Excel, PowerPoint).
• Solid organizational Skills and detailed oriented
• Strong Writing Skills

Desired Qualifications and Skills:

• Fundamental understanding of other disciplines including stress, dynamics, thermal analysis, production, electronics, systems engineering, etc.
• Experience with composite design and layup
• Experience with DFM/A
• Experience transitioning a product to production
• Experience with Risk Management
• Familiarity with Military standards relating to the mechanical design of aircraft.
• Familiarity with Engineering Change Requests/Orders ECR/Os
• Experience with a gated design process/workflow
• Experience with supplier management and procurement (such as SOWs, RFPs, and/or vendor management)

Comprehensive Benefits & Perks:

• Health & Wellness: Choose from three health, dental, and vision plans - including a 100% employer-paid option covering both employees and their families.
• Paid Time Off: Enjoy 120 hours of PTO, 80 hours accrued plus an additional 40 hours of holiday break pay in addition to Christmas Eve, Christmas Day, and New Year’s Day off.
• Life Insurance: $25,000 employer-paid life insurance policy, with the option to purchase additional coverage for employees and their families.
• Supplemental Coverage: Access optional benefits such as Critical Illness, Hospital Indemnity, Accident Insurance, and Critical Illness with Skin Cancer coverage.
• Health Savings Account (HSA): Take advantage of a tax-advantaged HSA to manage medical expenses.
• Retirement Savings: 401(k) with a company match to support your financial future.
• Paid Holidays: Enjoy 9 paid holidays throughout the year.
• Work Environment: A casual dress code, complimentary snacks, and a welcoming company culture.
• Ideal Location: Work in an area that offers an outstanding quality of life - a perfect place to live, work, and play!

Company Overview:

Empirical Systems Aerospace, Inc (ESAero) is a leader in aerospace engineering, product development, and manufacturing, dedicated to delivering high-quality, innovative, and cost-effective solutions to the industry. We specialize in cutting-edge system design, rapid product development, precision manufacturing, comprehensive testing, and technology demonstrations to support the evolving needs of the aerospace community. Committed to excellence, on-time delivery, and continuous growth, we invest in infrastructure to expand our manufacturing and aftermarket capabilities while maintaining the highest standards of engineering services.

At ESAero, we don’t just build products, we engineer solutions that propel

the aerospace industry forward.

This position is fully on-site at ESAero in San Luis Obispo, CA

ESAero is an equal opportunity employer.
E-Verify participation required for employment.
Must present proof of authorization to work in the United States.
Must be able to pass background check and drug test.
Hiring Range: $130k-175k Salary/Exempt