Mechanical Design Analysis Engineer Jobs in Virginia

Join a fast-scaling aerospace startup and set the standard for mechanical engineering excellence.

As a Senior Mechanical Engineer at our Crozet, Virginia location, you will own the full mechanical design lifecycle for high-reliability avionics and power electronics subsystems from concept through release on aggressive program timelines. You will design and analyze enclosures, thermal management solutions, and structural interfaces for hardware that is already flying on key customer UAS, eVTOL, and unmanned platforms.

Allocor.techs commitment to enabling the next generation of advanced air mobility is built upon a foundation of hard-working and motivated individuals who collaborate, challenge, and have each others backs. Join a driven team thats tackling challenging projects, delivering flight-critical hardware, and making a real impact on the future of unmanned and electric aviation.

(Please note: this position can be hired at the Senior Mechanical Engineer I or Senior Mechanical Engineer II or III level.)
What Youll Own

• Lead mechanical design of major subsystems (enclosures, thermal management, structural mounts) using SolidWorks and SolidWorks PDM
• Perform FEA and CFD analysis to validate heat rejection, vibration response, structural integrity, and environmental performance for high-power avionics hardware
• Own complete technical data packages (TDPs) for customer and internal programs, ensuring AS9100-compliant documentation, revision control, and release processes
• Collaborate closely with electrical engineering on packaging, connector placement, thermal interface materials, and integration of power electronics assemblies
• Support prototype fabrication, first-article inspection, GD&T definition, and vendor communication to ensure designs are manufacturable and meet requirements
• Drive mechanical design reviews (PDR, CDR), presenting analysis results, trade studies, and risk assessments to cross-functional stakeholders and customers
• Mentor junior mechanical engineers and co-ops on design standards, simulation best practices, GD&T, and configuration-controlled documentationbuilding how mechanical engineering is executed at Allocortech

YOULL BRING THESE QUALIFICATIONS AS A SENIOR MECHANICAL ENGINEER:

• Bachelors degree in Mechanical Engineering or equivalent (MS preferred)
• 5+ years of mechanical design engineering experience focused on electronic enclosures, thermal management, or electromechanical systems
• Expert-level proficiency in SolidWorks (parts, assemblies, drawings) and SolidWorks PDM (or equivalent PLM/configuration management system)
• Demonstrated experience performing structural and thermal FEA (SolidWorks Simulation, ANSYS, or equivalent)
• Strong command of GD&T per ASME Y14.5 and mechanical drawing standards
• Experience creating and managing technical data packages in a configuration-controlled environment

These Qualifications Would Be Nice To Have

• Experience designing for aerospace or defense applications with DO-160 or MIL-STD environmental qualification requirements
• CFD analysis experience (ANSYS Fluent, FloTHERM, or equivalent) for forced-air or liquid cooling systems
• Familiarity with AS9100 design control, document release processes, and quality management expectations
• Hands-on DFM/DFA experience with sheet metal, CNC machining, and injection molding

This position may require prolonged periods of sitting, standing, walking, computer work, and occasional exposure to moderate levels of noise, dust, and fumes in production areas.
Level and base salary will be determined on a case-by-case basis and may vary based on the following considerations: job-related knowledge and skills, education, and experience. Base salary is just one component of our total rewards package. Employees may also receive company equity and access to a robust benefits package including: top tier medical HMO, PPO & a 100% company-sponsored HSA plan option, dental and vision coverage, unlimited PTO, 11 paid holidays per year, flexible spending and dependent care savings accounts, paid parental leave, disability insurance, life insurance, and access to a 401(k) retirement plan with company match. Eligibility for benefits may vary based on employment status, please check with your recruiter for a comprehensive list of the benefits available for this role. Benefit programs are subject to change at the companys discretion.
About Allocortech

Allocortech is a nimble, high-growth company delivering safety-critical power electronics, avionics, and flight control systems for next-generation UAS, eVTOL, and unmanned platforms. Our hardware is already flying on key customer programs and demand is accelerating.

We move fast, make decisions close to the work, and scale deliberately while protecting the quality and responsiveness that differentiate us. Youll have direct ownership of real flight hardware deliverables, the chance to shape mechanical engineering processes as we grow, and the opportunity to mentor the next generation of engineers all while working in the outstanding quality of life of Virginias Shenandoah Valley.

Important Information
FOR CANDIDATES SEEKING TO WORK IN US OFFICES ONLY:
To conform to U.S. Government technology export regulations, including the International Traffic in Arms Regulations (ITAR), Allocor.Tech Employees must be a U.S. citizen, lawful U.S. permanent resident (i.e., current Green Card holder), or lawfully admitted into the U.S. as a refugee or granted asylum, or be eligible to obtain the required authorizations from the U.S. Department of State and/or the U.S. Department of Commerce, as applicable.
Allocor.tech provides equal employment opportunities to all employees and applicants for employment and prohibits discrimination and harassment of any type without regard to race, color, religion, age, sex, national origin, disability status, genetics, protected veteran status, sexual orientation, gender identity or expression, or any other characteristic protected by federal, state, or local laws. This policy applies to all terms and conditions of employment at Allocor.Tech, including recruiting, hiring, placement, promotion, termination, layoff, recall, transfer, leaves of absence, compensation, and training.

Apply NOW

We review applications on a rolling basis and move quickly for strong fits.

Allocor.tech is an equal opportunity employer. We celebrate diversity and are committed to creating an inclusive environment for all employees.