CA Sr Mechanical Engineer DFM/DFMEA SolidWorks

Senior Mechanical Engineer - Product Development & Validation

Location: Santa Ana, CA ( Orange County, CA)

Employment Type: Full-Time and Direct-Hire

Industry: Aerospace / Automotive / Defense Engineering

A dynamic engineering team is seeking a Senior Mechanical Engineer with a passion for innovation and a strong background in new product development. This role is ideal for a driven professional who thrives in a fast-paced environment and enjoys solving complex technical challenges from concept through production.

Key Responsibilities

Analyze technical data packages to develop design, validation, and production strategies.

Lead design reviews and drive Design for Manufacturing (DFM) initiatives.

Create and maintain Design Failure Mode and Effects Analyses (DFMEAs).

Conduct trade studies and mentor junior engineers while developing robust mechanical solutions.

Develop and execute comprehensive Design Verification Plans (DVP), including test procedures, equipment calibration, fixture planning, and formal reporting.

Oversee prototype builds and support full-scale production launches.

Manage project timelines and deliverables as needed to meet key milestones.

Required Qualifications

Minimum 5 years of mechanical engineering experience, preferably in aerospace, automotive, or defense sectors.

Proven experience in designing and launching complex mechanical systems.

Proficiency in SolidWorks, including recent hands-on design work.

Strong understanding of GD&T and tolerance stack-up analysis.

Familiarity with engineering risk management tools such as DFMEA and PFMEA.

Experience with systems engineering and/or power electronics is a plus.

Education

Bachelor's degree in Mechanical Engineering required.

Advanced technical degree preferred.

DOD/Defense/Aerospace product design experience and training is desired

Preferred Skills & Knowledge

Excellent communication and presentation skills for cross-functional collaboration.

Working knowledge of military standards and specifications (MIL, etc.) and the DoD technical review process.

Ability to perform Finite Element Analysis (FEA) and Computational Fluid Dynamics (CFD) using SolidWorks.

Comfortable working independently and collaboratively within a multidisciplinary team.

Why This Role?

This is a high-impact position offering the opportunity to work on cutting-edge technologies and contribute to meaningful product development efforts. If you're ready to take ownership of challenging projects and grow within a forward-thinking engineering environment, we encourage you to apply.

Benefits

Competitive salary commensurate with experience.

Comprehensive benefits package including medical, dental, and vision coverage.

401(k) retirement savings plan.

Paid time off and holidays.

Exciting and challenging work in a dynamic industry with opportunities for growth and advancement.