Senior Design Engineer

🚀 Job Opportunity: Senior Design Engineer
Location: Mansfield, Massachusetts, USA
Experience: 8–12 Years
🔒 Eligibility:
This role is open to Visa Independents only due to project requirements.
🔧 About the Role
We are seeking a highly skilled Senior Design Engineer with strong expertise in mechanical design and aerospace component development. The ideal candidate will bring deep technical knowledge, hands-on experience in advanced engineering tools, and the ability to collaborate effectively across cross-functional teams.
✅ Key Responsibilities
Perform engineering design analyses including tolerance stack-ups and hand calculations to ensure optimal fit, form, and function
Develop detailed mechanical designs, layouts, and drawings using CAD tools such as SolidWorks, Autodesk Inventor, and Siemens NX
Conduct FEA and CFD simulations using ANSYS or equivalent tools to validate structural, thermal, and performance requirements
Build and test prototypes to verify product functionality, safety, and reliability
Collaborate with manufacturing and supply chain teams to ensure Design for Manufacturability (DFM) and cost efficiency
Create and maintain Bill of Materials (BOMs), engineering documentation, and reports within PLM systems
Apply and review GD&T standards (ASME Y14.5) to ensure design accuracy and quality
Support certification and compliance activities (FAA, TCCA, OEM standards)
Participate in design reviews and provide technical leadership throughout the product lifecycle
Drive continuous improvement initiatives across engineering processes and tools
Communicate project status and updates effectively with stakeholders and customers
Ensure compliance with export control regulations
Travel locally to customer sites as required
🎯 Required Qualifications
Bachelor’s degree in Mechanical Engineering or a related discipline
8+ years of hands-on mechanical engineering experience
Strong proficiency in CAD tools: SolidWorks, Autodesk Inventor, Siemens NX
Experience with FEA/CFD analysis tools such as ANSYS
Proven experience in aerospace component design and analysis
Excellent communication and technical documentation skills
Ability to collaborate effectively in cross-functional teams
Strong customer-facing and stakeholder management skills
⭐ Preferred Qualifications
Experience designing hardware integrated with electronics or avionics systems
Knowledge of manufacturing processes and engineering outsourcing models
Exposure to project/program management
Experience in developing standard work, processes, and documentation
Commitment to core values such as integrity, accountability, continuous learning, and customer focus
💼 Physical Requirements
Ability to work at a desk for extended periods
Comfortable navigating manufacturing environments
Ability to lift up to 15 lbs when required
🌟 Why Join?
Work on cutting-edge aerospace technologies with a globally recognized industry leader, contributing to innovative engineering solutions and high-impact projects.
If you’re interested or know someone who fits this profile, feel free to connect or share the most updated CV with samuel@cygnuspro.com or Premkumar@cygnuspro.com
Show more Show less