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Senior Fea Engineer Jobs (NOW HIRING)

VPE Thermal LLC

FEA Mechanical Engineer

Sacramento, CA · On-site

$100K - $135K/yr

As an FEA mechanical engineer at VPE Thermal, your primary role will revolve around developing simulations of heat exchanger designs provided by a senior engineer. Your work will focus on thermal ...

AAR Corporation

Senior Staff Engineer - FEA

Cadillac, MI

$91K - $120K/yr

Conducts engineering analysis using FEA software to determine and certify the safety and performance of new designs. Works with design team to evaluate and refine initial engineering designs before ...

AAR

Senior Staff Engineer - FEA

Cadillac, MI · On-site

$91K - $120K/yr

Conducts engineering analysis using FEA software to determine and certify the safety and performance of new designs. Works with design team to evaluate and refine initial engineering designs before ...

AAR Corporation

Senior Staff Engineer - FEA

Cadillac, MI · On-site

$91K - $120K/yr

Conducts engineering analysis using FEA software to determine and certify the safety and performance of new designs. Works with design team to evaluate and refine initial engineering designs before ...

ICR

Senior Mechanical Engineer

Houston, TX · On-site

$90K - $118K/yr

The Senior Mechanical Engineer will work within the Engineering team, to support the technical ... Review and approve FEA reports completed by the global engineering team. * Determine when third ...

Managed Staffing

Senior Mechanical Engineer

Oro Valley, AZ · On-site

$45 - $50/hr

Senior Mechanical Engineer (Engineer III) Location: Oro Valley, AZ Contract Duration: 3 months to 1 ... Conduct Finite Element Analysis (FEA) -- both structural and thermal (ANSYS preferred) * Perform ...

ICR

Senior Mechanical Engineer

Houston, TX · On-site

$90K - $118K/yr

The Senior Mechanical Engineer will work within the Engineering team, to support the technical ... Review and approve FEA reports completed by the global engineering team. * Determine when third ...

Allocor Tech

Senior Mechanical Engineer

Crozet, VA · On-site

$96K - $127K/yr

Current senior engineers are oversubscribed across internal R&D and customer programs. This role ... Conduct FEA and CFD analysis to validate heat rejection, vibration response, and structural ...

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Senior Fea Engineer information

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$59.5K

$126.6K

$183.5K

How much do senior fea engineer jobs pay per year?

As of Jun 7, 2026, the average yearly pay for senior fea engineer in the United States is $126,557.00, according to ZipRecruiter salary data. Most workers in this role earn between $104,500.00 and $143,500.00 per year, depending on experience, location, and employer.

What are the key skills and qualifications needed to thrive in the Senior Fea Engineer position, and why are they important?

To thrive as a Senior FEA Engineer, you need advanced knowledge of finite element analysis principles, mechanical engineering concepts, and typically a bachelor's or master's degree in engineering. Expertise with FEA software such as ANSYS, Abaqus, or NASTRAN, along with proficiency in CAD tools and relevant industry certifications, is highly valued. Strong problem-solving skills, attention to detail, and the ability to communicate complex findings to multidisciplinary teams are crucial soft skills. These abilities ensure accurate simulations, effective collaboration, and innovative solutions in product design and structural analysis projects.

What are some common daily responsibilities for a Senior FEA Engineer?

A Senior FEA Engineer typically spends their workdays creating and validating finite element models, analyzing simulation results, and preparing detailed technical reports for project teams and stakeholders. You may collaborate closely with design engineers, project managers, and manufacturing teams to propose optimization solutions or address engineering challenges. Reviewing and mentoring the work of junior engineers and staying current with advancements in simulation tools are also common responsibilities. This role is highly collaborative, with frequent opportunities to influence product design decisions and ensure the structural integrity and performance of engineering solutions.

What is a Senior FEA Engineer job?

A Senior FEA (Finite Element Analysis) Engineer is responsible for performing advanced structural, thermal, and mechanical simulations to evaluate product designs. They use finite element methods to analyze stress, strain, fatigue, and other performance factors, ensuring products meet safety and performance standards. They also collaborate with design, manufacturing, and testing teams to optimize designs and troubleshoot engineering challenges. Strong knowledge of FEA software (such as ANSYS or Abaqus) and industry standards is essential. This role typically requires several years of experience in structural analysis, material behavior, and computational modeling.

More about Senior Fea Engineer jobs
What cities are hiring for Senior Fea Engineer jobs? Cities with the most Senior Fea Engineer job openings:
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Senior Fea Engineer jobs near you
Infographic showing various Senior Fea Engineer job openings in the United States as of May 2026, with employment types broken down into 1% As Needed, 82% Full Time, 14% Part Time, 1% Temporary, and 2% Contract. Highlights an 87% Physical, 5% Hybrid, and 8% Remote job distribution, with an average salary of $126,557 per year, or $60.8 per hour.
Senior Mechanical Design Engineer - Aerospace & UAV Systems

Senior Mechanical Design Engineer - Aerospace & UAV Systems

BlackStar

San Francisco, CA

$210K - $230K/yr

Full-time

Posted 5 days ago

Job description

Overview

We are building a safety-critical electromechanical system integrated into a small UAV platform. This role owns the end-to-end mechanical design of ruggedized, field-deployed hardware, including structural design, internal mechanisms, and mechanical safety architecture.

The system must reliably withstand vibration, shock, environmental exposure, and handling while maintaining strict fail-safe behavior across all operating states.

You will be responsible for taking mechanical systems from concept through CAD, prototyping, validation testing, and production handoff in a fast-iteration, small-team engineering environment.

Key Responsibilities

  • Design mechanical assemblies including housings, internal structures, and actuation/safety mechanisms using parametric CAD tools.
  • Develop mechanical safety architecture in collaboration with electrical and software teams (interlocks, fail-safe geometry, mechanical state constraints).
  • Define materials, finishes, tolerances, fasteners, and mechanical interfaces for harsh operating environments.
  • Build and iterate prototypes using in-house fabrication (3D printing, CNC machining, basic manual machining).
  • Execute mechanical validation testing including drop, shock, vibration, and environmental qualification.
  • Produce manufacturing-ready documentation (GD&T drawings, tolerance stacks, BOMs, and DFM packages).
  • Own system mass properties and center-of-gravity budgets for UAV integration.
  • Collaborate cross-functionally on system integration (PCB constraints, connectors, harness routing, mechanical actuation interfaces).
  • Support vendor engagement for machining, injection molding, and production scaling.

Required Qualifications

  • 5+ years of mechanical design experience in field-deployed, rugged, or regulated industries (UAV, aerospace, defense, automotive, or industrial systems).
  • Strong proficiency in parametric CAD (SolidWorks, Fusion 360, Onshape, Creo, NX, etc.).
  • Experience producing manufacturing-ready drawings (GD&T, tolerance analysis, fits, surface finishes).
  • Hands-on prototyping experience (3D printing, CNC machining, mill/lathe familiarity).
  • Strong understanding of failure modes and design-for-reliability principles.
  • Demonstrated end-to-end ownership: concept design prototype test production transfer.
  • Strong written and verbal English communication skills.

Preferred Qualifications

  • Experience with safety-critical mechanical systems (fail-safe mechanisms, safety interlocks, or similar regulated hardware).
  • Familiarity with environmental/qualification standards (MIL-STD-810 or equivalent).
  • Experience with FEA / structural simulation (Ansys, SolidWorks Simulation, or similar).
  • DFM experience for injection molding, metal casting, or precision manufacturing.
  • Background in UAV/FPV systems or mass/CG-sensitive mechanical design.

Work Environment

  • Small, high-ownership engineering team with fast iteration cycles (weekly hardware builds).
  • Close collaboration between mechanical, electrical, and software engineers.
  • Strong emphasis on test-driven design, rapid prototyping, and production readiness.
  • Engineers are expected to own systems end-to-end and actively challenge design constraints when needed.

Location & Onsite Requirement

  • Full-time onsite role (5 days/week).
  • Mandatory 1-month onsite training in Kearneysville, West Virginia.
  • After training, relocation to and onsite work from one of the following hubs:
    • San Francisco Bay Area, CA
    • Los Angeles, CA
    • Washington, DC Metro Area
  • Candidates must be willing to relocate; relocation assistance is not provided.

Mechanical Design Engineer, UAV mechanical engineer, aerospace hardware engineer, safety-critical systems, CAD design engineer, SolidWorks, GD&T, DFM engineer, prototyping engineer, CNC machining, UAV payload design, rugged systems engineer, mechanical systems engineer, FEA engineer, defense hardware engineering.