Mechanical Design Engineer

Job Title: Mechanical Design Engineer Ground Test Wind Tunnel Infrastructure

Job Description

This role focuses on designing and supporting ground test wind tunnel infrastructure for missile and hypersonic programs for a U.S. Army customer. You will lead cradle-to-grave mechanical design efforts for high-pressure, high-temperature piping and wind tunnel systems, develop prototype hardware, and collaborate closely with technicians and machinists to bring complex aerospace-related designs from concept through fabrication and test. This position offers the opportunity to contribute directly to innovative and impactful projects for the U.S. Department of Defense within a rapidly growing, employee-owned organization.

Responsibilities

• Design and develop prototype mechanical hardware to support ground test wind tunnel infrastructure for missile and hypersonic applications.
• Own cradle-to-grave design activities, including concept development, detailed design, documentation, fabrication support, and design refinement based on test results.
• Create detailed 3D models and engineering drawings using SolidWorks or similar CAD tools, ensuring accuracy and manufacturability.
• Design components and systems for manufacturing methods such as milling and turning operations, with a focus on high-pressure, high-temperature piping and wind tunnel systems.
• Develop and maintain complete Technical Data Packages (TDP), including drawings, bills of materials, and supporting documentation.
• Apply geometric dimensioning and tolerancing (GD&T) to ensure clear, precise, and functional design specifications.
• Interpret results from finite element analysis (FEA) tools, including Abaqus or similar, to inform and optimize mechanical designs.
• Collaborate with technicians and machinists on the shop floor and oversee the fabrication and assembly of prototypes to ensure designs are built as intended.
• Troubleshoot design and fabrication issues, providing technical guidance at both component and system levels.
• Incorporate AS9100-compliant processes and documentation practices into design and development activities, where applicable.
• Work closely with a small engineering team to share knowledge, review designs, and ensure high-quality deliverables for aerospace hardware.
• Support test activities and incorporate feedback from test results into iterative design improvements.
• Communicate design intent, status, and technical decisions clearly to internal stakeholders and project teams.
• Demonstrate a hands-on, invested approach by staying as needed to complete critical tasks and meet project deadlines.

Essential Skills

• U.S. citizenship and eligibility to obtain and maintain a Secret security clearance.
• Bachelors degree in Mechanical Engineering, Aerospace Engineering, or a similar STEM discipline.
• At least 5 years of relevant mechanical design experience; strong consideration may be given to candidates with slightly less experience if they closely match the required high-pressure, high-temperature piping and wind tunnel design work.
• Proven experience designing and developing prototype hardware from concept through fabrication.
• Proficiency with SolidWorks or other 3D CAD software, with the ability to quickly adapt to SolidWorks if experienced in tools such as Creo.
• Experience designing for manufacturing methods, including milling and turning operations.
• Demonstrated expertise in both component-level and system-level mechanical design.
• Experience with aerospace hardware or closely related high-performance mechanical systems.
• Working knowledge of geometric dimensioning and tolerancing (GD&T).
• Ability to collaborate effectively with technicians and machinists and support prototype fabrication activities onsite.
• Strong mechanical aptitude and hands-on approach to solving engineering problems.

Additional Skills & Qualifications

• Active Secret security clearance is preferred, though eligibility is the primary requirement.
• Familiarity with AS9100 processes and quality systems.
• Experience generating complete Technical Data Packages (TDP).
• Experience interpreting results from FEA analysis tools, such as Abaqus, to guide design decisions.
• Experience working with CNC machinery and understanding of CNC manufacturing constraints.
• Experience with high-pressure, high-temperature piping and wind tunnel systems.
• Exposure to multiple products or product lines, rather than a single legacy product, demonstrating versatility in design experience.
• Abaqus proficiency as the primary FEA software used is considered a strong plus.
• Evidence of mechanical hobbies or tinkering that demonstrate practical, hands-on mechanical aptitude.
• Interest in working within a team that includes engineers with a broad range of experience levels, from early career to highly experienced professionals.

Work Environment

This is an onsite role primarily based in Hollywood, Alabama, with the option to work from the headquarters in Huntsville and travel to Hollywood as needed, though the preference is for the engineer to spend more time in Hollywood. You will work closely with a team of approximately six engineers within a larger engineering organization of about 17 engineers and 30 technicians, enabling significant knowledge transfer and collaboration. The environment is highly collaborative, with daily interaction with technicians and machinists and direct oversight of prototype fabrication on the shop floor. Typical technician and machinist hours run from about 7:00 a.m. to 3:30 p.m., while engineering staff generally start between 8:00 a.m. and 8:30 a.m. and finish between 4:30 p.m. and 5:00 p.m., offering some flexibility within those windows. Team members are highly invested in delivering high-quality products and are willing to stay late when necessary to complete critical work. The culture emphasizes hands-on engineering, close coordination between design and manufacturing, and a strong commitment to supporting innovative and impactful projects for the U.S. Department of Defense within a growing, employee-owned company.

This is a Contract to Hire position based out of Hollywood, AL.

The pay range for this position is $48.00 - $65.00/hr.

Individual compensation offered for this position within this range will depend on many factors, including qualifications, skills, relevant experience, job knowledge, geographic location, internal equity, and other pertinent job-related factors.

Eligibility requirements apply to some benefits and may depend on your job classification and length of employment. Benefits are subject to change and may be subject to specific elections, plan, or program terms. If eligible, the benefits available for this temporary role may include the following: Medical, dental & vision Critical Illness, Accident, and Hospital 401(k) Retirement Plan Pre-tax and Roth post-tax contributions available Life Insurance (Voluntary Life & AD&D for the employee and dependents) Short and long-term disability Health Spending Account (HSA) Transportation benefits Employee Assistance Program Time Off/Leave (PTO, Vacation or Sick Leave)

This is a Contract to Hire position based out of Hollywood, AL.

This position is anticipated to close on Oct 29, 2026.

This is a fully onsite position in Hollywood,AL.

About Actalent

Actalent is a global leader in engineering and sciences services and talent solutions. We help visionary companies advance their engineering and science initiatives through access to specialized experts who drive scale, innovation and speed to market. With a network of almost 20,000 consultants and 5,000 clients across the U.S., Canada, Asia and Europe, Actalent serves many of the Fortune 500. We are proud to be an Engineering News-Record (ENR) Top 500 Design Firm for our engineering design services and a ClearlyRated Best of Staffing® winner for both client and talent service.

The company is an equal opportunity employer and will consider all applications withoutregard to race, sex, age, color, religion, national origin, veteran status, disability,sexual orientation, gender identity, genetic information or any characteristic protectedby law.

If you would like to request a reasonable accommodation, such as the modification oradjustment of the job application process or interviewing process due to a disability,please email for other accommodation options.

San Francisco Fair Chance Ordinance:Pursuant to the San Francisco Fair Chance Ordinance, for all positions located in thecity and county of San Francisco, we will consider for employment qualified applicantswith arrest and conviction records.

Massachusetts Lie Detector:It is unlawful in Massachusetts to require or administer a lie detector test as acondition of employment or continued employment. An employer who violates this lawshall be subject to criminal penalties and civil liability.

Use of Artificial Intelligence (AI):We may use Artificial Intelligence (AI) to support parts of our hiring process,including sourcing, screening, and evaluating candidates. AI helps assess applicationsand qualifications, but final decisions are made by our hiring team. By applying, youacknowledge and agree that your application may be reviewed using AI tools.