Job Description
POSITION TITLE
Mechanical Design Engineer - Aircraft Structures (SolidWorks) INDUSTRY
Aviation / Aircraft Manufacturing EMPLOYMENT TYPE
Full-Time | On-Site (Oshkosh, WI) | Remote Considered | Relocation Assistance Available ABOUT THE ROLE
Sonex Aviation is seeking a driven, hands-on Mechanical Design Engineer - Aircraft Structures to design and detail metal aircraft structures and customer build kits in SolidWorks for our Oshkosh, Wisconsin manufacturing operation. This role translates concepts, loads, and lessons-learned into manufacturable parts, clean drawings, and assemblies that move straight from the screen to the laser, the CNC, and the build floor. The right person will be detail-obsessed, fast-moving, and comfortable owning designs end-to-end without constant direction. This is not a slow, big-aerospace seat — we're looking for someone who takes ownership, sweats the dimensions, solves problems, and gets parts flying. IMPORTANT
This role requires hands-on production SolidWorks experience along with a working knowledge of sheet metal design and GD&T. Candidates without relevant mechanical or structural design experience may not be considered. ABOUT US
Sonex Aviation is an Oshkosh, Wisconsin-based aircraft manufacturer and one of the most recognized names in experimental and light sport aviation. Founded in 1998, our lineup includes the Sonex, Onex, Waiex-B, and the new Highwing, alongside the AeroConversions and Sonex Aerospace product lines. Under new ownership, we're entering the most ambitious chapter in our history—investing aggressively in R&D, modernizing how we design and build, and scaling production to clear a strong order book, including 80+ preorders for the Highwing. This is a build-it phase, not a maintain-it phase: smart, humble professionals who value accountability, execution, and craftsmanship, building airplanes that get everyday people into the sky. Learn more at:
www.sonexaircraft.com YOU MAY BE A GREAT FIT IF YOU
Have hands-on SolidWorks design experience across parts, assemblies, drawings, and sheet metal Think in load paths, fasteners, and tolerances—and sweat the details because someone downstream is cutting metal from them Take ownership of designs end-to-end and make decisions confidently without needing constant reassurance Thrive in a fast-paced, high-output environment where priorities may shift throughout the day Communicate clearly and professionally with the shop floor, manufacturing, vendors, and leadership Design for manufacturability—and for the homebuilder assembling the kit in their own shop Have a builder's mindset and like seeing your parts get made and fly WHAT YOU'LL DO
As the Mechanical Design Engineer - Aircraft Structures, you'll design and detail aircraft structures and kits in SolidWorks, working shoulder-to-shoulder with our lead designer, manufacturing team, and shop floor—with a short path from idea to part in hand. Key responsibilities include:
Design and detail aircraft structural components and assemblies in SolidWorks—primarily sheet metal aluminum, plus weldments, machined parts, and hardware Produce manufacturing-ready outputs: fully dimensioned drawings, flat patterns, DXFs for laser/CNC, and accurate BOMs Engineer for two customers at once—our production line and the homebuilder assembling the kit—designing for buildability with common tools and clear instructions Apply GD&T (ASME Y14.5) and sound tolerancing so parts fit, match-drill, and assemble correctly the first time Support structural decisions with sound judgment—load paths, joints, basic stress and fatigue reasoning—and run FEA (SolidWorks Simulation) where it adds value Design jigs, fixtures, and tooling that improve repeatability and throughput Manage CAD data, revisions, and configurations cleanly (PDM); keep drawings and BOMs accurate as designs evolve Build and revise builder and assembly documentation so kit customers succeed Prototype, fit-check, and iterate alongside the shop—then push improvements back into the design WHAT YOU NEED TO BRING
Bachelor's in Mechanical, Aerospace, or related engineering—or equivalent hands-on design experience that speaks for itself 3+ years of production SolidWorks experience: parts, assemblies, drawings, sheet metal, and large-assembly management Working command of GD&T (ASME Y14.5) and real-world tolerancing for fabricated and assembled parts Solid grasp of mechanical/structural fundamentals: load paths, fasteners and joints, and basic stress concepts Experience designing parts that get made—sheet metal forming, laser/waterjet, CNC machining—with strong DFM/DFA instincts Strong drawing discipline and meticulous attention to detail Self-directed and comfortable in a lean, fast-moving environment Preferred:
aircraft structures, experimental/LSA, or kit/homebuilt aircraft experience Preferred:
SolidWorks Simulation (FEA), CAM, or PDM administration experience Preferred:
you're a pilot, EAA member, or builder who lives and breathes aviation COMPENSATION & BENEFITS
Salary:
$70,000 - $120,000 (based on experience) Relocation assistance available for the right candidate Medical, dental & vision insurance — company-shared premiums Paid Time Off (PTO) and paid holidays 401(k) with employer match A high-impact role where your designs fly—not sit in a backlog READY TO BUILD AIRPLANES?
If you take initiative, sweat the details, and want your CAD work flying on real aircraft—let's talk. Send your resume and a portfolio or samples of your SolidWorks work (drawings, sheet metal parts, assemblies) to [email / application link]. Tell us about a part you designed that got manufactured, and what you'd change about it now. Sonex Aviation is an Equal Opportunity Employer. All qualified candidates are encouraged to apply. Pay:
$70,000.00 - $120,000.00 per year Benefits:
401(k) 401(k) matching Dental insurance Health insurance Paid time off Relocation assistance Vision insurance Application Question(s): Are you located in, or willing to relocate to, the Oshkosh, WI area? (Relocation assistance may be provided.)? Education:
Bachelor's (Preferred) Experience:
SolidWorks:
3 years (Required) mechanical or structural design: 1 year (Preferred) Work Location:
In person
