Zachary Piper Solutions is currently seeking a Mechanical Engineer to support aviation, defense, and commercial aircraft modification efforts based in Hagerstown, MD . This is a full-time, primarily onsite role supporting mission-critical engineering programs that require FAA-compliant aircraft structural modifications and payload integration. As a Mechanical Engineer, you will play a key role in the design, analysis, and integration of aircraft structural modifications and payload mounts, working cross-functionally with electrical engineering, fabrication teams, DER/ODA representatives, and customers to deliver safe, certifiable, and reliable solutions.

Key Responsibilities

• Design, analyze, and validate aircraft structural modifications and payload mounting solutions in accordance with FAA regulations and mission requirements
• Perform structural substantiation including free-body diagrams, static load calculations, and stress analysis
• Develop detailed 3D models and 2D engineering drawings using SolidWorks in compliance with ASME Y14.5 GD&T standards
• Research, evaluate, and select mechanical hardware and components; coordinate with approved vendors and OEMs
• Troubleshoot mechanical and integrated aircraft systems using appropriate testing and measurement equipment
• Prepare and issue RFQs and provide complete technical documentation to fabrication partners
• Serve as the primary engineering point of contact for fabrication, assembly, and aircraft installation teams
• Interface with FAA DER/ODA representatives to support certification and airworthiness approvals
• Support customer communication, project tracking, and technical status updates
• Provide technical guidance and on-the-job training to internal teams as needed
• Support domestic and international travel for aircraft installations and customer support (ranging from days to multiple weeks)

Required Qualifications

• Bachelor's degree in Mechanical Engineering or Aeronautical Engineering
• 4-6 years of relevant engineering experience
• Experience supporting aviation or defense programs
• Working knowledge of FAA procedures, regulations, and certification requirements
• Proficiency with SolidWorks for 3D modeling and 2D drawing creation
• Strong understanding of aircraft structures and mechanical systems
• Ability to interpret and produce technical drawings and engineering documentation
• Active DoD Secret clearance - will get Top Secret
• Valid driver's license and ability to pass DOT/FAA drug screening
• Ability to obtain and maintain a passport

Preferred Qualifications

• Advanced SolidWorks proficiency
• Experience supporting ISR aviation platforms
• Direct experience with FAA safety and certification efforts
• Prior experience training personnel on aircraft mechanical systems

Position Details

• Schedule: Monday - Friday, 8:00 a.m. - 5:00 p.m.
• (Flexibility for evenings/weekends as mission demands)
• Travel: Domestic and international travel required
• Location: Hagerstown, Maryland

Compensation & Benefits

• Salary Range: $70,000 - $92,000 *depending on experience*
• Benefits Package: Medical, Dental, Vision, 401(k), PTO, and Sick Leave (where required by law)

This job opens for applications on 4/21/26 and will remain open for at least 30 days from the posting date.

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Keywords: Mechanical Engineer, Aircraft Structures, FAA Certification, DER, ODA, Aircraft Modifications, Payload Integration, SolidWorks, GD&T, ASME Y14.5, Structural Analysis, Static Load Analysis, Aviation Engineering, Defense Engineering, ISR Aviation, Aircraft Installation, Aerospace Engineering, Fabrication Support, OEM Coordination, Airworthiness Certification