Sr. Design Engineer (Thrust Integration)

We’re ALTEN Technology USA, an engineering company helping clients bring groundbreaking ideas to life—from advancing space exploration and life-saving medical devices to building autonomous electric vehicles. With 3,000+ experts across North America, we partner with leading companies in aerospace, medical devices, robotics, automotive, commercial vehicles, EVs, rail, and more.

As part of the global ALTEN Group—57,000+ engineers in 30 countries—we deliver across the entire product development cycle, from consulting to full project outsourcing.

When you join ALTEN Technology USA, you’ll collaborate on some of the world’s toughest engineering challenges, supported by mentorship, career growth opportunities, and comprehensive benefits. We take pride in fostering a culture where employees feel valued, supported, and inspired to grow.

As Sr. Design Engineer (Thrust Integration) you will be responsible for;

• Design and Engineering
• Develop and maintain CAD and drawings to document interfaces between thrust unit subsystems and airframe interfaces
• Own and maintain thrust unit envelope CAD models and keep out zones to enable comprehensive vehicle package studies
• Own thrust unit configuration management, tracking various pedigrees and versions of hardware
• Lead detailed design and development of the thrust unit attach hardware from concept through production
• Assist in fairing integration design to optimize aerodynamic and thermal performance and system accessibility
• Interface with maintenance team to ensure thrust unit designs meet serviceability goals and enable efficient maintenance operations
• Collaborate with manufacturing team to ensure seamless aircraft integration processes, optimize assembly tooling design, and develop suitable shipping and handling solutions
• Analysis and Project Management
• Own and maintain comprehensive mass budget tracking for all thrust unit subsystems, identifying risks and weight optimization opportunities
• Perform structural and thermal analysis of thrust unit components using FEA tools
• Conduct trade studies to optimize system integration, mass efficiency, and performance
• Support test planning and validation activities for thrust unit assemblies
• Analyze test data and implement design improvements based on findings
• Leadership and Collaboration
• Collaborate with vehicle integration, airframe, aerodynamics, loads, and systems teams to ensure integrated thrust unit meets all requirements
• Work cross-functionally with sourcing and quality teams to support supplier selection, component qualification, and inspection requirements for integration components
• Participate in design reviews and provide technical expertise for critical integration decisions

Qualifications;

• Education & Experience
• Bachelor's Degree in mechanical/aerospace engineering, or related field
• Minimum of 4+ years of mechanical design experience, preferably in aerospace or automotive systems
• Proven experience with system-level integration, interface management, and mount design
• Experience with propulsion system integration or similar rotating machinery applications
• Experience generating Bills of Materials (BOM) and managing change control processes
• Technical Expertise
• Proficiency in CAD modeling (NX preferred), 2D drawings, tolerance analysis, and GD&T
• Strong understanding of structural analysis and FEA software packages (ANSYS, NASTRAN preferred)
• Knowledge of aerospace fastening methods, mounting systems, and structural interfaces
• Experience with mass budgeting, configuration management, and systems integration
• Understanding of manufacturing processes for aerospace structural components
• Communication and Organization
• Proven ability to coordinate cross-functional technical initiatives across multiple subsystem teams
• Excellent documentation and communication skills for maintaining complex interface requirements
• Capacity to manage multiple integration challenges and priorities simultaneously
• Strong analytical and problem-solving skills for resolving interface conflicts
• Additional Requirements
• Availability for domestic travel as needed
• Demonstrated commitment to safety and quality in engineering practices

Preferred Qualifications;

• Aerospace development and certification experience
• Experience with electric propulsion systems or hybrid powertrains
• Background in aircraft structural design and certification requirements
• Self-motivated with exceptio