{"id":745376,"url":"https://alion.io/job/odysaviation-senior-mechanical-design-engineer-propulsion","title":"Senior Mechanical Design Engineer [Propulsion]","company":{"id":678914,"name":"odysaviation","domain":"odysaviation.com","url":"https://alion.io/company/odysaviation","size_band":"51-200","is_staffing_agency":false,"employer_type":"direct","is_intermediary":false,"listed_via":null,"ats_vendor":"Ashby","truth_index":{"grade":"B","score":70,"open_postings":16,"ghost_share":0.5,"stale_share":0,"repost_share":0,"time_to_fill_p50_days":null,"computed_at":"2026-11-11T05:49:22Z"}},"role":"Aerospace","role_family":"Aerospace","seniority":"senior","employment_type":"full_time","work_mode":"on_site","remote_scope":null,"remote_scope_basis":null,"remote_working_hours":null,"hiring_geo_confidence":"structured","locations":["Long Beach, United States"],"countries":["US"],"hiring_countries":[],"hiring_countries_total":0,"salary":{"min":125000,"max":200000,"currency":"USD","period":"year","gross":null,"usd_annual":200000},"salary_estimate":null,"experience_years_min":null,"visa_sponsorship":false,"relocation_package":false,"has_equity":false,"technologies":[{"name":"GD&T","optional":false}],"status":"live","first_seen_at":"2026-09-09T15:20:16Z","employer_posted_date":"2026-09-09","last_verified_at":"2026-11-11T16:18:04Z","board_verified":true,"closed_at":null,"days_open":63,"trust":{"level":"ok","repost_count":0,"flags":["company_stale"],"days_open":62},"description":"About Odys\nAt Odys, we’re mobilizing power, with Hybrid Power Systems developed for aerospace and in-demand everywhere. It’s the kind of mission diversity that demands a fresh way of thinking.\nWe began with an early bet on hybrid, when the mobility industry was focused on batteries. We designed, tested, and validated our first 1 MW high-speed generator in 12 months. And then we pushed further, developing systems with greater power density in less time. Today, our Hybrid Power Systems offer outputs ranging from 20 kW to 4 MW, with applications in the air or on the ground.\nOne of those applications is Laila, an unmanned drone designed for critical logistics and defense missions. With its 100 kW-class onboard Hybrid Power System, Laila can support medical cold-chain transport or serve as an aerial platform for counter-UAS measures.\nThe market interest has been overwhelming: Over 30 inbound requests from leading US and global manufacturers, and 14+ DoD contracts.\nOur team comes from deep tech and aerospace, with backgrounds spanning drone and aircraft development, high-volume production, and electrified mobility.\nWe operate with urgency and ownership at every level. We validated high-speed generator technology faster than our peers, not because we skipped steps, but because we've been doing this long enough to know which ones matter most.\nCreating the future of power, in the air and on the ground, is a challenge we’ve been training our entire lives for. If that sounds like you, this is the opportunity you’ve been waiting for.\nAbout The Role\nOdys Aviation is seeking a senior level Mechanical Design Engineer to join our Propulsion Team. In this role, you will design, analyze, and integrate mechanical and thermal systems that support high-power hybrid-electric propulsion, including motors, generators, inverters, turbines and their supporting structures and cooling systems.\nYou’ll work closely with electrical, manufacturing, test, and flight teams. This is a hands-on role with ownership of critical hardware, where you will play a key role as we mature our propulsion systems.\nDon't meet all desired requirements? Studies have shown that some people are less likely to apply to jobs unless they meet every single desired qualification. At Odys, we are dedicated to building an authentic workplace, so if you're excited about this role but your past experience doesn't align perfectly with every desired qualification in the job description, we encourage you to apply anyway.\nWhat You’ll Do\nLead design and analysis of rotating machinery subsystems (turbines, motors, generators), addressing vibration, dynamic balancing, and bearing/seal challenges\n\nDrive resolution of real hardware issues discovered during prototype and early production builds\n\nMentor and provide technical guidance to mid-level and junior engineers\n\nContribute to planning and technical strategy for the propulsion team, including design reviews and technical standards\n\nCreate and maintain 3D CAD models and 2D drawings, including GD&T and tolerance stackups\n\nPerform DFM/DFA trade studies, balancing weight, cost, thermal performance, reliability, and manufacturability\n\nWork with suppliers and internal teams to assess manufacturing feasibility, refine designs, and rapidly resolve build issues\n\nSupport hands-on prototype assembly, integration, and test, including debugging and root cause analysis\n\nConduct engineering analysis using a mix of hand calculations and FEA to inform design decisions\n\nImplement and refine thermal management strategies (air and/or liquid cooling, heat sinks, TIMs, enclosures, insulation)\n\nTranslate test data and build feedback into actionable design improvements\n\nDocument designs, analyses, and design changes clearly to support team alignment and future production\n\nWhat We’re Looking For\nB.S. or M.S. in Mechanical Engineering, Aerospace Engineering, or a related field\n\nExperience with high speed rotating machinery and associated challenges (ex. vibration, critical speed, dynamic balancing, bearings/seals)\n\n5+ min years of experience in mechanical design of complex systems\n\nDemonstrated experience owning and delivering on a critical assembly or subsystem with ownership from concept through build, test through production\n\nProficiency in 3D CAD (NX preferred) and creating production-quality drawings with GD&T\n\nStrong understanding of tolerance stack-ups and real-world fit/integration challenges\n\nExperience designing for a range of manufacturing processes (machining, sheet metal, additive, etc.)\n\nHands-on experience building, testing, and troubleshooting hardware\n\nComfortable working on electromechanical systems (motors, power electronics, rotating machinery, batteries, cooling systems, etc.)\n\nDemonstrated ability to debug issues, perform root cause analysis, and drive corrective actions\n\nExperience working in fast-paced, iterative hardware development environments\n\nStrong problem-solving skills, attention to detail, and bias toward action\n\nClear communicator who collaborates effectively across multidisciplinary teams\n\nTechnical leadership experience (ex. leading design reviews, mentoring engineers, or setting technical standards for the team)\n\nNice to Have\nExperience with propulsion systems or electromechanical systems\n\nBackground in thermal management of high-power systems (liquid cooling, forced air, heat exchangers)\n\nExperience with rotor dynamics or vibration analysis tools (e.g., modal analysis, critical-speed analysis)\n\nExperience performing thermal and/or structural analysis (FEA, analytical modeling, or CFD)\n\nExperience supporting prototype builds and early production environments\n\nFamiliarity with PLM systems (Teamcenter preferred)\n\nBackground in aerospace, automotive (EV/powertrain), robotics, or similar high-performance hardware 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