Sr. Mechanical Engineer

Aerospace is at a turning point - costs are rising, supply chains are strained, and old ways of building can’t keep up. At Neon Aero, we’re breaking that mold. We move fast, think big, and combine start-up agility with aerospace expertise to design, build, and scale aircraft in ways the industry has never seen. Our team leverages automation, AI-driven tools, and a fully connected digital backbone to accelerate innovation and reduce barriers to production.

Here, you won’t just take a job - you’ll help reinvent how the world flies. If you’re ready to solve complex problems, push technology further, and work alongside some of the brightest minds in aerospace, this is your chance to make a real impact.

Neon Aero is looking for a Senior Mechanical Engineer to lead the design and integration of complex mechanical and electromechanical systems for next-generation hardware. You’ll work across high-performance domains- positioning, propulsion, environmental control, energy management, and related technologies-supporting programs in aerospace, advanced mobility, robotics, and transportation.

This is a hands-on, highly collaborative role for an engineer who loves turning requirements into production-intent hardware that scales. You’ll help architect robust systems, drive design into manufacturable solutions, and push hardware from concept → prototype → industrialization → shipment.

Why This Role Matters:

In this role, you’ll be a key driver of system-level execution-owning critical subsystems and making early decisions that determine whether hardware ships on time, at cost, and at quality.

You will:

• Lead mechanical system design and integration across complex, multi-domain programs.
• Own a subsystem end-to-end, from architecture and concept to production release.
• Design and develop mechanical/electromechanical assemblies in Siemens NX (required).
• Drive early DFM, DFA, DFAuto, and DFC decisions to ensure designs scale to production.
• Apply strong GD&T fundamentals to create production-ready drawings and specs.
• Partner with suppliers and manufacturing teams to industrialize parts, including first article builds and production ramp.
• Define inspection approaches and understand manufacturing metrics like IQC, OQC, ORT, CP/CPK, tolerance stack-ups, and validation.
• Support prototype builds, test campaigns, root-cause investigations, and design iterations.
• Perform mechanical analysis as needed (FEA, thermal evaluation, structural validation).
• Participate in design reviews and ensure performance, safety, reliability, cost, and schedule targets are met.
• Provide hands-on support during assembly, integration, and testing-because the best systems engineers stay close to the hardware.

What you’ll Bring:

• Minimum of 8 years of experience in developing and shipping mechanical products
• Bachelor’s or Master’s in Mechanical Engineering or related degree is preferred; relevant professional experience may be accepted in lieu of a degree.
• Strong proficiency in Siemens NX is required.
• Deep knowledge of GD&T and production-level drawing release practices.
• Demonstrated experience bringing parts into production and shipping hardware.
• Experience with multiple manufacturing processes, such as:
  • Sheet metal fabrication
  • Die casting
  • Gear manufacturing & finishing
  • High-precision machining (HPM/HDPM)
  • Injection molding or other scalable processes
• Proven ability to work directly with suppliers to resolve tolerance, yield, and quality issues.
• Solid understanding of quality systems and metrics: IQC, OQC, ORT, CP/CPK, SPC.
• Strong cross-functional communication skills and a collaborative, systems-level mindset.

Preferred experience:

• Aerospace or aviation systems experience.
• Background in fast-iteration, high-performance environments (automotive, consumer hardware, racing, robotics, etc.).
• Familiarity with DO-160 or similar environmental qualification standards.
• MATLAB or Python for analysis/automation.
• Experience with electric or hybrid propulsion systems.

Why Join Us:

• Work alongside elite engineering talent and innovators from across aerospace and tech.
• Be part of a team moving faster than the industry standard.
• Shape solutions that are lower-cost, autonomous, and scalable - the future of aviation.
• Competitive compensation, including equity participation, growth opportunities, and full heath benefits (health, vision, dental, 401K) designed to support you in and out of work.

This is the expected compensation range for this role. Final compensation will be based on role scope, experience, skills, internal equity and location. This role may also be eligible for bonus/equity/benefits, if applicable.

$150,000—$250,000 USD

Neon Aero, Inc is an Equal Opportunity Employer. We celebrate diversity and are committed to creating an inclusive environment for all employees. We do not discriminate on the basis of race, religion, color, national origin, gender, sexual orientation, gender identity or expression, age, disability, veteran status, or any other protected status under applicable law.

We believe that diverse perspectives drive innovation, and we welcome candidates from all backgrounds to apply.

All final candidates must successfully complete a background check and drug screening as a condition of employment.

At this time, Neon Aero and its divisions are not accepting unsolicited resumes from third-party recruiters or staffing agencies.