Senior Design Engineer

🚀 Job Opportunity: Senior Design EngineerLocation: Mansfield, Massachusetts, USAExperience: 8–12 Years🔒 Eligibility: This role is open to Visa Independents only due to project requirements.🔧 About the RoleWe 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 ResponsibilitiesPerform engineering design analyses including tolerance stack-ups and hand calculations to ensure optimal fit, form, and functionDevelop detailed mechanical designs, layouts, and drawings using CAD tools such as SolidWorks, Autodesk Inventor, and Siemens NXConduct FEA and CFD simulations using ANSYS or equivalent tools to validate structural, thermal, and performance requirementsBuild and test prototypes to verify product functionality, safety, and reliabilityCollaborate with manufacturing and supply chain teams to ensure Design for Manufacturability (DFM) and cost efficiencyCreate and maintain Bill of Materials (BOMs), engineering documentation, and reports within PLM systemsApply and review GD&T standards (ASME Y14.5) to ensure design accuracy and qualitySupport certification and compliance activities (FAA, TCCA, OEM standards)Participate in design reviews and provide technical leadership throughout the product lifecycleDrive continuous improvement initiatives across engineering processes and toolsCommunicate project status and updates effectively with stakeholders and customersEnsure compliance with export control regulationsTravel locally to customer sites as required🎯 Required QualificationsBachelor’s degree in Mechanical Engineering or a related discipline8+ years of hands-on mechanical engineering experienceStrong proficiency in CAD tools: SolidWorks, Autodesk Inventor, Siemens NXExperience with FEA/CFD analysis tools such as ANSYSProven experience in aerospace component design and analysisExcellent communication and technical documentation skillsAbility to collaborate effectively in cross-functional teamsStrong customer-facing and stakeholder management skills⭐ Preferred QualificationsExperience designing hardware integrated with electronics or avionics systemsKnowledge of manufacturing processes and engineering outsourcing modelsExposure to project/program managementExperience in developing standard work, processes, and documentationCommitment to core values such as integrity, accountability, continuous learning, and customer focus💼 Physical RequirementsAbility to work at a desk for extended periodsComfortable navigating manufacturing environmentsAbility 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