Mechanical Engineer at INNOVATIVE AEROSYSTEMS – EXTON, Pennsylvania

The Mechanical Engineer will lead the design and development of mechanical components and assemblies for advanced electro-mechanical products. This role works closely with cross-functional engineering teams, program management, manufacturing, and supply chain to ensure high-quality, manufacturable designs that meet customer and regulatory requirements. The ideal candidate is a hands-on engineer with strong CAD skills, a solid understanding of mechanical design principles, and experience designing for production.

Key Responsibilities:

Product Design & Development

• Design and develop company products using CAD tools based on customer requirements, specifications, and system constraints.
• Perform detailed mechanical design work including sheet metal, gearing, castings, and injection-molded plastic components.
• Conduct finite element analysis (FEA) and apply sound engineering judgment to ensure structural integrity and performance.
• Apply Design for Manufacturability (DFM) and value engineering principles to reduce part count, manufacturing cost, and product complexity while maintaining performance and reliability.

Cross-Functional Collaboration

• Partner with Program Managers and Systems/Project Engineers to ensure designs meet all customer, compliance, and certification requirements.
• Collaborate closely with Electrical Engineers to ensure seamless integration of electronic components and mechanical assemblies.
• Work directly with machine shop personnel and procurement to support efficient prototype fabrication.
• Coordinate with Manufacturing Engineers to implement designs optimized for assembly, cost, and repeatability.

Configuration Management & Documentation

• Update and maintain legacy designs, ensuring alignment with current CAD standards and drawing revision control.
• Create and manage complete drawing packages, BOMs, and engineering documentation.

Leadership & Support

• Train and guide team members in assembly procedures and best practices.
• Communicate proactively, collaborate effectively, and contribute positively to the IA engineering team environment.

Professional Expectations

All IA team members are expected to:

• Ask questions when presented with tasks outside their physical or professional capabilities.
• Uphold safety, facility security, and protection of proprietary technologies and information.

Required Qualifications

• BSME with 3–4+ years of relevant mechanical design experience.
• Demonstrated electro-mechanical design experience, including sheet metal, gearing, castings, and injection-molded plastics.
• Proficiency with PTC Creo / Pro-E.
• Experience with FEA, precision manufacturing processes, and instrument-level assembly methods.
• Strong knowledge of materials, coatings, and finishes used in mechanical design.
• Experience with electronic packaging and/or avionics environments is highly desirable.
• Familiarity with lighting and optical components is a plus.
• Due to compliance with U.S. export control laws and regulations, candidate must be a U.S. citizen, U.S. permanent resident, or have asylum or refugee status in the U.S.

Performance Metrics

Success in this role will be measured by:

• Quality, reliability, and manufacturability of mechanical designs.
• Timely completion of engineering tasks and project milestones.
• Effective collaboration with internal teams and external stakeholders.

Equal Opportunity Employer/Veterans/Disabled.

IA is an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, or protected veteran status and will not be discriminated against on the basis of disability.