A Mechanical Engineer researches, designs, develops, constructs, and tests mechanical devices including machines, engines and tools. Works on devices ranging from power generators to household dishwashers to surgical equipment. May specialize in a particular type of machine or tool. May develop new devices or improve existing ones to run more efficiently.
Job Summary Ansync Labs bridges the gap between digital design and physical manufacturing. By maintaining an on-site production facility alongside our multidisciplinary engineering teams, we replace traditional hand-offs with a seamless, end-to-end development cycle. We are seeking a Senior Mechanical Engineer with a strong background in aerospace, defense, or high-reliability hardware environments to lead complex mechanical design programs from concept through physical realization. In this role, you won't just be creating CAD models—you will architect hardware, lead technical trade studies, perform critical stress and environmental analyses, and work steps away from our in-house machine shop and PCBA production floor. You will bring the rigor of aerospace standards (GD&T, high-precision DFM, thermal/structural analysis) into an agile, rapid-development environment, taking total ownership of client projects and mentoring multidisciplinary teams along the way.
Lead the mechanical design, structural packaging, and architecture of complex systems for aerospace, defense, robotics, and industrial automation using Autodesk Inventor (or equivalent high-end 3D CAD).
End-to-End Program Ownership:
Drive the complete mechanical lifecycle from preliminary design reviews (PDR) and critical design reviews (CDR) to prototyping, verification, and low-rate production. Take full technical and timeline ownership of deliverables.
Analysis & Validation:
Perform structural, thermal, and dynamic analyses (FEA, hand calculations, tolerance stack-ups) to ensure designs withstand harsh operational environments (shock, vibration, extreme temperatures).
High-Precision DFM/DFA & Shop Collaboration:
Apply rigorous Design for Manufacturability and Assembly principles. Work directly alongside on-site CNC machinists and fabricators to optimize parts for high-precision machining, sheet metal, and additive manufacturing.
Cross-Functional System Integration:
Partner closely with electrical and software teams to solve complex electro-mechanical packaging, thermal management, and sensor/actuator integration challenges.
Technical Documentation & Quality:
Author comprehensive engineering documentation, including fully dimensioned manufacturing drawings (per
ASME Y14.5
), Bills of Materials (BOMs), engineering change orders (ECOs), and test plans aligned with high-reliability quality standards.
Client & Stakeholder Management:
Serve as the primary technical point of contact for clients, confidently presenting engineering trade-offs, managing expectations, and navigating technical risks without requiring oversight.
Mentorship & Process Improvement:
Mentor junior and mid-level engineers, driving continuous improvement in internal engineering processes, CAD methodologies, and design standards.
Requirements Professional Experience:
6+ years of mechanical design experience in aerospace, defense, space systems, or high-reliability hardware development environments.
Education:
Bachelor's or Master's degree in Mechanical Engineering, Aerospace Engineering, or a related technical discipline.
CAD & Analysis Mastery:
Expert-level command of 3D CAD (Autodesk Inventor preferred; SolidWorks/Creo accepted) and integrated FEA analysis tools (ANSYS, Nastran, or equivalent).
GD&T & Precision DFM:
Deep expertise in Geometric Dimensioning and Tolerancing (GD&T per
ASME Y14.5
), worst-case/rss tolerance stack-up analysis, and material selection for demanding environments (titanium, aerospace aluminum, high-performance plastics, composites).
Hands-on Hardware Experience:
Strong desire and track record of working directly on the shop floor, validating prototypes, building test fixtures, and troubleshooting physical hardware hardware.
Regulatory & Industry Standards:
Familiarity with aerospace/defense standards and environmental testing (e.g., MIL-STD-810, DO-160, AS9100 quality management systems, or space-flight hardware packaging).
Project & Client Leadership:
Demonstrated capability to manage client relationships, balance competing project constraints, and deliver complex mechanical systems on time and within budget.
Communication:
Exceptional written and verbal communication skills, with the ability to articulate complex technical trade-offs to both executive clients and shop-floor technicians. Preferred Qualifications Experience with
ITAR/EAR
compliant programs and controlled technical data workflows. Familiarity with CNC programming principles, rapid tooling, and advanced manufacturing processes. Background in electro-mechanical packaging, ingress protection (IP ratings), electromagnetic isolation, and thermal management for high-density electronics.
Compensation & Benefits:
Base Salary Range:
$[130,000] -$[175,000] (commensurate with experience and level)
Work Location & Schedule:
Location:
El Dorado Hills, CA 95762
Work Model:
On-site, Mon-Fri, 40-45 hours per week
Travel:
Up to 10% travel for client reviews, field testing, and supplier audits.
Pay:
$90,000.00 - $120,000.00 per year
Benefits:
401(k) 401(k) matching Dental insurance Flexible schedule Health insurance Paid time off Vision insurance
