Mechanical Design Engineer [Propulsion]

Odys Aviation is seeking a mid level Mechanical Design Engineer to join our Propulsion Team. In this role, you will design, analyze, and integrate mechanical and thermal systems that support high-power hybrid-electric propulsion, including motors, generators, inverters, turbines and their supporting structures and cooling systems.

You’ll work closely with electrical, manufacturing, test, and flight teams to take hardware from early concept through prototype build, test, and iteration. This is a hands-on role with meaningful ownership and a strong growth path as our propulsion systems mature and move toward production.

Don't meet all desired requirements? Studies have shown that some people are less likely to apply to jobs unless they meet every single desired qualification. At Odys, we are dedicated to building an authentic workplace, so if you're excited about this role but your past experience doesn't align perfectly with every desired qualification in the job description, we encourage you to apply anyway.

1. Own the mechanical design and integration of propulsion components and subsystems (motors, generators, inverters, turbines, structures and cooling systems)

2. Drive resolution of real hardware issues discovered during prototype and early production builds

3. Create and maintain 3D CAD models and 2D drawings, including GD&T and tolerance stackups

4. Perform DFM/DFA trade studies, balancing weight, cost, thermal performance, reliability, and manufacturability

5. Work with suppliers and internal teams to assess manufacturing feasibility, refine designs, and rapidly resolve build issues

6. Support hands-on prototype assembly, integration, and test, including debugging and root cause analysis

7. Conduct engineering analysis using a mix of hand calculations and FEA to inform design decisions

8. Implement and refine thermal management strategies (air and/or liquid cooling, heat sinks, TIMs, enclosures, insulation)

9. Translate test data and build feedback into actionable design improvements

10. Document designs, analyses, and design changes clearly to support team alignment and future production

1. B.S. or M.S. in Mechanical Engineering, Aerospace Engineering, or a related field

2. 4+ years of experience in mechanical design of complex systems (or equivalent demonstrated capability)

3. Experience owning the design of a critical assembly or subsystem from concept through build, test, and iteration

4. Proficiency in 3D CAD (NX preferred) and creating production-quality drawings with GD&T

5. Strong understanding of tolerance stack-ups and real-world fit/integration challenges

6. Experience designing for a range of manufacturing processes (machining, sheet metal, additive, etc.)

8. Comfortable working on electromechanical systems (motors, power electronics, rotating machinery, batteries, cooling systems, etc.)

9. Demonstrated ability to debug issues, perform root cause analysis, and drive corrective actions

10. Experience working in fast-paced, iterative hardware development environments

11. Strong problem-solving skills, attention to detail, and bias toward action

12. Clear communicator who collaborates effectively across multidisciplinary teams

2. Familiarity with rotating machinery, vibration, and structural dynamics considerations

3. Background in thermal management of high-power systems (liquid cooling, forced air, heat exchangers)

4. Experience performing thermal and/or structural analysis (FEA, analytical modeling, or CFD)

5. Experience supporting prototype builds and early production environments

7. Background in aerospace, automotive (EV/powertrain), robotics, or similar high-performance hardware industries