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Zulu Pods, Inc. · 2 months ago

Principal Mechanical Design Engineer, Level 5

Northampton, MA

Full-time

Onsite

Lead/Staff

9+ years exp

Zulu Pods, Inc. is building America's next-generation component and sub-system company, and they are seeking a highly motivated Principal Mechanical Design Engineer. The selected individual will lead the design, analysis, and validation of complex fluidic components and systems for various aerospace applications, while also mentoring junior engineers and contributing to the development of patented technology.

AerospaceAir TransportationMilitary

No H1B

Security Clearance Required

U.S. Citizen Only

Responsibilities

Design and Analysis: Lead the design, analysis, and validation of complex fluidic components and systems (e.g., propulsion systems, thermal management, fuel systems) for various aerospace applications

System Integration: Oversee the integration of fluidic and mechanical subsystems into larger aerospace platforms, ensuring performance, safety, and reliability requirements are met

Modeling and Simulation: Develop and apply advanced computational fluid dynamics (CFD) models and other analytical tools to predict, optimize, and troubleshoot system behavior

Testing and Validation: Plan, execute, and analyze results from ground and flight tests to validate system performance against design specifications, iterating as necessary

Requirements Management: Translate high-level mission and system requirements into detailed fluidic and mechanical component specifications

Problem Solving: Rapidly diagnose and resolve complex technical issues related to fluid mechanics, system performance anomalies, and hardware failures

Documentation: Generate and maintain detailed engineering documentation, including requirements specifications, design documents, test reports, and manufacturing procedures, adhering to industry standards

Collaboration: Work with cross-functional teams (engineers, designers, operations, and program management) to successfully execute projects on time and within design scope

Technical Leadership: Demonstrated ability to act as the System Architect or Lead Responsible Engineer (LRE) for a major subsystem. Ability to mentor junior engineers and effectively present complex technical data and trade studies to internal stakeholders and external customers

Qualification

Mechanical DesignFluid DynamicsComputational Fluid DynamicsSystem IntegrationTestingValidationModelingSimulationMechanical PackagingRobust Mechanical DesignProblem SolvingTeamworkCommunicationAdaptability

Required

Education: Bachelor's or Master's Degree in Mechanical Engineering, Aerospace Engineering, or a closely related field

Experience: Minimum of 9 years of professional experience in fluidics, mechanical packaging, and mechanical system technologies

System Design & Analysis: Proven history of leading the design, analysis, and validation of complex aerospace fluidic subsystems. This includes propulsion components (valves, injectors, turbo-machinery interfaces), high-pressure hydraulics/pneumatics, or advanced thermal management loops (single-phase/two-phase)

Advanced Fluid Dynamics & CFD: Expert-level proficiency in compressible and incompressible fluid dynamics, heat transfer, and thermodynamics. Extensive, applied experience developing, executing, and interpreting results from complex Computational Fluid Dynamics (CFD) simulations, including turbulence modeling, transient flows, and fluid-structure interaction (FSI)

Modeling & Simulation: Exceptional skill in using analytical and system-level modeling tools to develop dynamic models of fluidic and mechanical systems for performance prediction, control loop design, and fault analysis

Testing and Validation: Expertise in defining, instrumenting, and executing rigorous component and system-level tests. Advanced skill in data acquisition and post-processing to correlate test results with analytical models and validate performance margins

Robust Mechanical Design: Deep understanding of mechanical design principles, including stress analysis (FEA), fatigue life, material selection for extreme environments, and design for manufacturability (DFM) and assembly (DFA)

Complex Component Packaging: Extensive experience in the 3D packaging and routing of intricate fluidic and mechanical systems within strict, confined aerospace envelopes

Hardware Ownership: Demonstrated ability to drive a component or system from concept/PDR through CDR, prototyping, full-scale production, and successful flight/mission operation

Tools: Expert-level proficiency with professional CAD software (e.g., SolidWorks, CATIA, NX) for part/assembly modeling, drawing creation (GD&T per ASME Y14.5), and configuration management. Expertise with FEA (e.g. ANSYS) and system-level modeling tools (e.g., MATLAB/Simulink)

Excellent problem-solving skills and attention to detail

Strong communication and teamwork abilities

Ability to learn quickly and adapt to new technologies

0-25% Travel as required by job responsibilities

US Citizenship or Permanent Residency (due to the nature of defense-related work)

Preferred

Rocket Propulsion Experience: Direct, hands-on experience in the design, development, or testing of liquid rocket engines (LREs), including high-performance components like injectors, turbopumps, and high-pressure valves. Experience with in-space propulsion or hypersonic fluid dynamics is highly valued

Complex Control Systems: Experience designing or integrating fluidic systems that incorporate closed-loop control mechanisms, including familiarity with Proportional-Integral-Derivative (PID) tuning and system stability analysis

Materials Science for Extreme Environments: In-depth familiarity with advanced materials suitable for extreme aerospace conditions, such as superalloys, composites, or refractory metals, especially regarding their interaction with propellants and high-temperature gases

Additive Manufacturing (AM): Practical experience designing aerospace hardware for additive manufacturing (3D printing), including knowledge of process limitations, post-processing requirements, and qualification/testing of AM parts

Industry Certifications/Experience: Experience working within AS9100 or other strict aerospace quality management systems

Benefits

Competitive salary and equity options

Comprehensive Health Insurance: Standard offerings include medical, dental, and vision insurance

Disability Insurance: Company-paid basic Short-Term Disability (STD) and Long-Term Disability (LTD) insurance to ensure financial security

Generous Paid Time Off (PTO): Competitive policies for vacation, sick, and personal days

Paid Parental Leave: Substantial time off for new parents

Career Acceleration: Join early in our growth journey to position yourself for future leadership opportunities as we expand; your impact today helps shape the company and opens doors to senior roles tomorrow

Influence and Autonomy: Senior engineers are often granted a high degree of technical autonomy and direct influence over core product decisions and architecture

Office Amenities: Stocked kitchens with unlimited snacks and gourmet coffee, team game nights, and team-building events

Personal Fulfillment: A stimulating, high-impact environment where your work directly contributes to national security and technological advancement