Senior Mechanical Engineer Mechanical Design & Analysis

Join a fast-scaling aerospace startup and set the standard for mechanical engineering excellence.

Allocortech is a nimble, high-growth company delivering safety-critical power electronics, avionics, and flight control systems for next-generation UAS, eVTOL, and unmanned platforms. Our hardware is already flying on key customer programs, and demand is accelerating.

Engineering Services is currently capacity-constrained. Senior engineers are stretched across internal R&D and customer work, creating risk for on-time, on-spec delivery. We need a dedicated Senior Mechanical Engineer who will own major subsystems from concept through release, protect program schedules, and build the mechanical engineering standards and processes that will scale with the company as we pursue higher production volumes and AS9100 maturity.

Why This Role Exists

Engineering Services lacks sufficient senior mechanical engineering bandwidth. As a result, customer contracts go unbilled and delivery timelines slip on programs that depend on robust enclosures, thermal management solutions, and precisely engineered structural interfaces. Current senior resources are oversubscribed balancing internal development with multiple active customer efforts.

This role adds focused senior-level mechanical engineering capacity and ownership. You will lead the full mechanical design lifecycle for high-reliability avionics subsystems, perform the required thermal and structural analysis, manage complete technical data packages, and—most importantly—establish repeatable design standards, simulation workflows, documentation practices, and mentoring approaches that allow the mechanical engineering function to grow efficiently and support Allocortech’s scaling trajectory.

What You’ll Own

• Lead mechanical design for major subsystems including enclosures, thermal management solutions, and structural mounts using SolidWorks and SolidWorks PDM.
• Perform FEA and CFD analysis to validate heat rejection, vibration response, structural integrity, and environmental performance for high-power avionics hardware.
• Own and manage complete technical data packages (TDPs) for customer and internal programs, ensuring AS9100-compliant documentation, revision control, and release processes.
• Collaborate closely with electrical engineering on packaging, connector placement, thermal interface materials, and integration of power electronics assemblies.
• Support prototype fabrication, first-article inspection, GD&T definition, and vendor communication to ensure designs are manufacturable and meet requirements.
• Drive mechanical design reviews (PDR, CDR), presenting analysis results, trade studies, and risk assessments to cross-functional stakeholders and customers.
• Mentor junior mechanical engineers and co-ops on design standards, simulation best practices, GD&T application, and configuration-controlled documentation for how mechanical engineering is executed at Allocortech.

Required

What You Bring

• 5+ years of mechanical design engineering experience focused on electronic enclosures, thermal management, or electromechanical systems.
• Expert-level proficiency in SolidWorks (parts, assemblies, drawings) and SolidWorks PDM or equivalent PLM/configuration management system.
• Demonstrated experience performing FEA for structural and thermal analysis (SolidWorks Simulation, ANSYS, or equivalent).
• Strong command of GD&T per ASME Y14.5 and mechanical drawing standards.
• Experience creating and managing technical data packages in a configuration-controlled environment.
• BSME or equivalent (MSME preferred).

Preferred

• Experience designing for aerospace or defense applications with DO-160 or MIL-STD environmental qualification requirements.
• CFD analysis experience (ANSYS Fluent, FloTHERM, or equivalent) for forced-air or liquid cooling systems.
• Familiarity with AS9100 design control, document release processes, and quality management expectations.
• Hands-on DFM/DFA experience with sheet metal, CNC machining, and injection molding processes.

Why You’ll Love It Here

This is a high-impact, foundational role in a small, agile team where your designs will go into real flight hardware on active customer programs. You’ll have direct ownership of the mechanical engineering contribution to major deliverables, the opportunity to shape processes and standards as we grow, and the chance to mentor the next generation of engineers.

We move fast, make decisions close to the work, and are scaling deliberately while maintaining the quality and responsiveness that differentiate us from larger, slower aerospace suppliers. The Shenandoah Valley offers an outstanding quality of life, and you’ll work alongside a talented, collaborative group that takes pride in delivering hardware that performs in demanding environments.

If you’re excited by the opportunity to join a growing startup, protect critical customer programs, and build the mechanical engineering foundation for the next phase of Allocortech’s growth, we’d love to talk.

Apply NOW

We review applications on a rolling basis and move quickly for strong fits.

Allocortech is an equal opportunity employer. We celebrate diversity and are committed to creating an inclusive environment for all employees.