Senior Design Engineer
Confirmed on the employer's own hiring board on Oct 29, 2026. First seen by Alion on Oct 28, 2026. Senior scores B on the Alion truth index.
For more than 70 years, Senior Metal Bellows has been pushing the limits of innovation-designing and building custom-engineered metal bellows for industries that demand the best: aerospace, defense, energy, and beyond.
We’re not just making parts-we’re making solutions no one else can. And we want you to be part of it.
We are seeking an experienced and innovative Senior Design Engineer to lead the design and development of complex engineered products and support our continued growth.
This position offers the opportunity to work on highly customized solutions, collaborate with cross-functional teams, and directly impact product performance, manufacturability, and customer success.
What You'll Do
The Senior Design Engineer is responsible for the design, development, and validation of custom metal bellows, assemblies, tooling, fixtures, and related products. The ideal candidate possesses a strong mechanical engineering background, advanced SolidWorks proficiency, and experience translating customer requirements into practical, manufacturable solutions. This role works closely with engineering, manufacturing, quality, operations, and sales teams to develop innovative products that meet technical, commercial, and customer objectives.
Key Responsibilities:
- Design and develop custom metal bellows, assemblies, tooling, and fixtures utilizing SolidWorks and ASME Y14.5 standards.
- Create detailed engineering drawings, 3D models, bills of materials, and technical documentation to support manufacturing and customer requirements
- Translate customer specifications, technical requirements, and engineering proposals into robust product designs.
- Apply Geometric Dimensioning and Tolerancing (GD&T), Design for Manufacturability and Assembly (DFMA), and engineering best practices throughout the product development process.
- Conduct or support Finite Element Analysis (FEA) and other engineering analyses to validate designs and improve performance.
- Apply engineering fundamentals and back-of-the-envelope calculations to validate analysis.
- Collaborate with manufacturing, quality, and production teams to optimize designs for performance, quality, cost, and manufacturability.
- Support prototype fabrication, testing, design verification, validation, and product qualification activities.
- Participate in customer meetings, technical reviews, and engineering discussions to support business development and project execution.
- Identify opportunities for continuous improvement and contribute to enhancements in engineering processes, tools, and standards.
- Provide technical leadership and mentorship to junior engineering staff as needed.
What You Bring:
- Bachelor's degree in Mechanical Engineering or a related engineering discipline.
- Minimum of 5 years of mechanical product design experience within a manufacturing environment.
- Minimum of 1 year of practical experience using FEA and engineering analysis tools.
- Poses a core understanding of FEA principals and willingness to grow our simulation capabilities without making it your sole focus.
- Proficiency with SolidWorks and Product Data Management (PDM) and/or Product Lifecycle Management (PLM) systems.
- Strong understanding of mechanical design principles, engineering drawings, and ASME Y14.5 Geometric Dimensioning and Tolerancing (GD&T) standards.
- Experience developing products from concept through production, including design, prototyping, testing, and manufacturing support.
- Excellent analytical, problem-solving, communication, and cross-functional collaboration skills.
- Ability to manage multiple projects and priorities in a fast-paced manufacturing environment.
A Bonus if You Have:
- Experience performing advanced mechanical analysis related to mechanical systems, pressure vessels, or structural components.
- A desire to conduct mechanical characterization of bellows products corelating empirical data with analytical and FEA models.
- Hands on experience using SolidWorks Simulation or ANSYS FEA packages
- Advanced knowledge of Design for Manufacturability and Assembly (DFMA) principles for high mix product lines.
- Experience working with custom-engineered products, tooling, fixtures, or precision manufacturing processes.
- Familiarity with quality systems, continuous improvement methodologies, and engineering change management processes.
Salary Hiring Range: $115,000 - $130,000
Trade Compliance Statement Access to our facilities is restricted under the International Traffic in Arms Regulations (ITAR) and/or the Export Administration Regulations (EAR) to U.S. Persons (U.S. Citizens, lawful permanent residents, U.S. Nationals, U.S. refugees, asylees, or temporary residents under amnesty provisions ), and to properly licensed foreign persons. Applicants receiving a conditional offer of employment will be required to provide information to determine whether they are subject to these regulations and, if so, to assess their country of chargeability for export control purposes. Additionally, potential employee names will be screened against the Consolidated Screening List (maintained by the United States government) to determine eligibility to receive controlled technical data.
To ensure there is no unexpected delay to your start date with our Company and due to the potential need to obtain an export license, we would like to promptly assess whether such a license is needed to access our facility and/or systems. Such licenses can take several weeks/months to obtain from the U.S. Government. Our Trade Compliance department may reach out to you with a Licensing Assessment form, which we request you kindly complete and return as soon as possible.
Reasonable accommodations may be made to enable individuals with disabilities to perform essential functions. EOE M/F/D/V/VEVRAA Federal Contractor