Sr. Design Engineer - AeroMechanical Structures

730 Lincoln Lake Ave Lowell MI 49331
Mechanical Engineering /

Interviews begin March 2024

Portfolio Required
In – Person
8+ Years of experience.

You (the Senior Design Engineer) will be responsible for designing, simulating, prototyping, and testing airframe structures and mechanisms for Orb’s family of hybrid eVTOL vehicles. Some of these structures include (but are not limited to) wings, fuselage, doors, nacelle tilt mechanisms, landing gear and the powerplant mounting system.

You should be a passionate air-framer/composite structural engineer with experience in nonconventional aircraft manufacturing and rapid development programs. You will make decisions every day that have a tangible impact on our mission. May be required to travel for demonstrations. Orb is a fast-paced and deadline-driven environment - the ideal candidate should be ready to hit the ground running.

Other duties of the Senior Design Engineer:

    • Mentor junior engineers in the design, assembly, and validation of flight worthy hardware.
    • Create and implement tools/documents to maximize design team productivity.
    • Develop full designs, drawing packages, BOMs, and assembly instructions for assigned vehicle program(s).
    • Lead the integration of designs and ensure that the systems meet the predetermined design requirements.
    • Manage the hardware and tool needs of the design team and provide recommendations for investment.
    • Support research efforts in conceptual-level mechanical design, analysis, and optimization, using scripting platforms like MatLAB/Simulink and Python.
    • Sign-off parts, assemblies, and drawings using Orb’s internal engineering control workflows, and PLM software.
    • Support requirements definition, conceptual/preliminary layout, and detailed analysis for vehicle systems.
    • Plan, perform and assist with lab, field, flight, and environmental testing.
    • Stay up to date on new technologies, aircraft configurations, materials, and manufacturing processes in support of ongoing and future programs and participate in the conception of novel aircraft mechanical systems and configurations.
    • Perform aerodynamic, structural, vibratory, and propulsive analysis, at several levels of fidelity to confirm designs match predetermined design requirements.
    • Perform trade studies from "first principles" and basic engineering fundamentals to drive a design from ideation to mass-manufacturing.
    • Rapidly prototype and vet design concepts using handmade models, programming environments, spreadsheets, and CAD software.

Required Skills:

    • Experience with the design of additively manufactured parts, machined parts, composite parts, injection molded parts, sheet metal parts, wire assemblies, and mechanical assemblies for low, medium, and high-volume manufacturing processes.
    • Demonstrated ability to solve complex structural dynamics problems, along with an understanding of metallic, plastic, and composite material properties.
    • Experience in prototype manufacturing in a fast-paced environment. Including creating MBOMs, and engineering drawings (to GD&T standards) for fabrication shop handoff.
    • Proficient in CAD workflows, authoring process, and equipment documentation.
    • Excellent problem solving and teamwork skills while working with cross-functional teams.
    • Ability to scale responsibilities appropriately as the team/company grows.
    • Experience in mechanical design and fabrication of heavily loaded components and structures, as well as high-precision components.
    • Knowledge of and experience in CFD, FEA (NASTRAN, FEMAP, Ansys, etc), heat transfer, structural dynamics analysis.  
    • Experience with project execution from initial ideation to decommissioning.  

Desired Skills:

    • Masters or Ph.D in relevant discipline 
    • 10+ years of work experience in relevant industry 
    • Project management experience
    • Experience with the design of lightweight structures, heavily loaded structures, and actuators, including COTS hardware selection and implementation.
    • Experience designing aircraft flight hardware and/or ground support equipment.
    • Hands on machine shop skills using CNCs, 3D printers, lathe, mill, welder, and other machine shop equipment.
    • Demonstrated understanding of industry design and documentation standards including, but not limited to GD&T, ASME, ASTM, ISO, etc.
    • Performed ground vibration/acoustic/flutter analysis on aircraft structures.
    • Experience with aircraft FAA certification processes
    • Familiarity with Siemens NX/TeamCenter/Fibersim.
    • Experimental Aircraft homebuilding is a plus!

Ideal Attributes:

    • Organized
    • Humble
    • Self-starter
    • Excellent communicator capable of pitching the company.
    • Motivated to learn new skills.
    • Passionate about Orb’s mission.
    • Interest in Aviation.
$80,000 - $120,000 a year
Most engineers come to Orb to join an early team with unprecedented freedom to build the world's largest humanitarian air force. We have a healthy standard equity rate that vests after one year.