Senior Mechanical Analysis Engineer, Structures

What the role needs

• Own vehicle structural sizing from preliminary architecture through detailed design including major load bearing structure, skins, spars, ribs, equipment mounts, and structural interfaces.
• Work alongside chief and design engineers using hand calculations and FEA to develop efficient load path structures, material selection, joint configurations, and other design decisions.
• Work closely with manufacturing, test, loads, and other engineering teams to develop practical, buildable structural solutions.
• Support structural testing, design reviews, prototype builds, and rapid design iterations as vehicle requirements and architectures mature
• Ability to support critical development and test milestones, including occasional extended hours and weekends as needed
• Generate sizing documentation, analysis reports, structural margins, engineering drawings, and supporting technical documentation for design reviews and hardware release
• Act as ‘analysis’ signoff reviewer for engineering data package releases across the program.
• Bachelor’s degree or higher in Mechanical Engineering, Aerospace Engineering, or a related discipline.
• 5+ years of experience in aerospace structural analysis optimization for strength and stiffness including metallics, composites, and bolted/bonded joints.
• Strong understanding of structural mechanics, load paths, free-body diagrams, strength, stiffness, stability, and structural sizing.
• Proficiency with CAD and structural analysis tools such as NX, FEMAP, Nastran, ANSYS, Abaqus, or equivalent to perform end to end structural analysis.
• Demonstrated ownership of structural hardware from initial concept through analysis, detailed design, manufacturing, and test.

From the employer

About Mach Industries Founded in 2023, Mach Industries is a rapidly growing defense technology company focused on developing next-generation autonomous defense platforms. At the core of our mission is the commitment to delivering scalable, decentralized defense systems that enhance the strategic capabilities of the United States and its allies. With a workforce of approximately 350 employees, we operate with startup agility and ambition. Our vision is to redefine the future of warfare through cutting-edge manufacturing, innovation at speed, and unwavering focus on national security. We are dedicated to solving the next generation of warfare with lethal systems that deter kinetic conflict and protect global security. The Role Mach is seeking a Senior Structural Engineer to own structural sizing and optimization of primary and secondary structure across our next-gen aerospace platforms via 1st order hand calculations as well has finite element analysis. You will build structural finite element models to write structural margins of safety for lightweight, high-performance airframe structures including metallics, composites, bonded joints, and bolted joints. You will support design-analysis cycles working hand in hand with designers, load and dynamics, and flight sciences teams. You will drive trade studies at the vehicle, subassembly and component level balancing mass, strength, stiffness, performance, and manufacturability at scale. Working alongside test and loads teams, you can validate designs, and correlate models, via structural or dynamic testing. You will write analytic reports and trade studies validating designs for presentation to peers and leadership. Additionally, you will help establish structural design best practices, mentor other engineers, and accelerate the development of hardware across the program. Key Responsibilities Own vehicle structural sizing from preliminary architecture through detailed design including major load bearing structure, skins, spars, ribs, equipment mounts, and structural interfaces. Work alongside chief and design engineers using hand calculations and FEA to develop efficient load path structures, material selection, joint configurations, and other design decisions. Work closely with manufacturing, test, loads, and other engineering teams to develop practical, buildable structural solutions. Support structural testing, design reviews, prototype builds, and rapid design iterations as vehicle requirements and architectures mature Ability to support critical development and test milestones, including occasional extended hours and weekends as needed Generate sizing documentation, analysis reports, structural margins, engineering drawings, and supporting technical documentation for design reviews and hardware release Act as ‘analysis’ signoff reviewer for engineering data package releases across the program. Required Qualifications Bachelor’s degree or higher in Mechanical Engineering, Aerospace Engineering, or a related discipline. 5+ years of experience in aerospace structural analysis optimization for strength and stiffness including metallics, composites, and bolted/bonded joints. Strong understanding of structural mechanics, load paths, free-body diagrams, strength, stiffness, stability, and structural sizing. Proficiency with CAD and structural analysis tools such as NX, FEMAP, Nastran, ANSYS, Abaqus, or equivalent to perform end to end structural analysis. Demonstrated ownership of structural hardware from initial concept through analysis, detailed design, manufacturing, and test. Preferred Qualifications Experience developing and maintaining vehicle-level global finite element models (GFEMs) and using them to support structural design and load development. Experience with aircraft/UAV structures such as fuselages, wings, control surfaces, spars, bulkheads, and major structural interfaces. Experience performing linear, non-linear, modal, and dynamic analyses including sine, random, and acoustic excitation. Experience performing fatigue and crack propagation analysis for metallics Experience supporting structural testing, FEM correlation, modal/buckling analysis, and flight-test hardware. Experience developing structural analysis reports, documenting margins of safety, and supporting engineering design reviews and hardware release. Experience with rapid prototype development and hands-on manufacturing or assembly of aerospace structures. Additional Requirements Available to work extended hours and weekends as needed ITAR Requirements To conform to U.S. Government export regulations, applicant must be a (i) U.S. citizen or national, (ii) U.S. lawful, permanent resident (aka green card holder), (iii) Refugee under 8 U.S.C. § 1157, or (iv) Asylee under 8 U.S.C. § 1158, or be eligible to obtain the required authorizations from the U.S. Department of State. Learn more about the ITAR here . Engineer $140,000 — $180,000 USD At Mach, we believe that compensation is more than just a paycheck. It's a comprehensive package designed to reward the time, skills, and expertise you bring to our team. We are committed to offering competitive compensation that is equitable, transparent, and aligned with market trends. Key Elements of Our Compensation Philosophy: Competitive Salaries : We continuously research market rates to ensure our salaries are competitive with those in our industry and geographic location. Performance-Based Incentives : Our bonus structure is tied to both individual and company performance, creating a win-win scenario that motivates our team members to excel. Equity Participation : We offer stock options or equity to employees, ensuring that you share in the success and growth of the company. Benefit Packages : Our benefits include healthcare, dental and vision plans, retirement savings, and paid time off, because we understand that your well-being extends beyond the office. Professional Development : We allocate funds for continuing education, training, and career growth. Transparency : We are committed to openness about our compensation tiers and how decisions are made, ensuring trust and mutual respect. By joining Mach, you’re not just accepting a job—you’re becoming a key part of a team that values your contributions and invests in your growth. Together, we aim to create a rewarding environment that sets the stage for long-term success. Data Privacy To view Mach Industries candidate data privacy policy, please visit https://machindustries.com/privacy-policy . Disclosures This position may require access to information protected under U.S. export control laws and regulations, including the Export Administration Regulations (EAR) and the International Traffic in Arms Regulations (ITAR). Please note that any offer for employment may be conditioned on authorization to receive software or technology controlled under these U.S. export control laws and regulations without sponsorship for an export license. Mach participates in E-Verify and will provide the federal government with your Form I-9 information to confirm that you are authorized to work in the U.S. The salary range for this role is an estimate based on a wide range of compensation factors, inclusive of base salary only. Actual salary offers may vary based on (but not limited to) work experience, education and training, critical skills, and business considerations. Highly competitive equity grants are included in most offers and are considered part of Mach’s total compensation package. Mach offers benefits such as health insurance, retirement plans, and opportunities for professional development. Mach is an equal opportunity employer committed to creating a diverse and inclusive workplace. All qualified applicants will be treated with respect and receive equal consideration for employment without regard to race, color, creed, religion, sex, gender identity, sexual orientation, national origin, disability, uniform service, Veteran status, age, or any other protected characteristic per federal, state, or local law, including those with a criminal history, in a manner consistent with the requirements of applicable state and local laws. If you’d like to defend the American way of life, please reach out!