Mechanical Design Engineer

Mechanical Design Engineer at Thales Alenia Space

Thales Alenia Space, a joint venture between Thales (67%) and Leonardo (33%), is a global leader in space manufacturing. For over 40 years, we have delivered high-tech solutions across telecommunications, navigation, Earth Observation, environmental management, exploration, science, and orbital infrastructures. Our diverse team and extensive expertise empower our customers – governments, institutions, space agencies, and telecom operators – to connect, secure, defend, observe, protect, explore, travel, and navigate in space.

We are actively seeking a Mechanical Design Engineer to join our team.

Role Overview

The Mechanical Design Engineer will be responsible for defining project solutions for structure subsystems within space mission vehicles, utilizing both metallic and composite materials. This role involves analyzing requirements at the structure subsystem level, which will form the foundation for design definition. You will define design solutions for structural parts and interfaces, carefully selecting appropriate materials, processes, and mechanical components.

A critical aspect of this role is developing mass-efficient structural solutions that synergize with selected aerospace materials. These solutions must withstand launch and mission loads, as well as potential re-entry and impact loads. Proficiency in FEM analyses is required to support identified design solutions, including detailed local models to assess critical areas. The Mechanical Design Engineer will also support the structural development process through dedicated test articles and breadboards designed to validate designs and analyses. Strong knowledge of CAD and drafting is essential to guide the elaboration of proposed design solutions. Additionally, you will be expected to coach and mentor junior team members, fostering their skill development.

Key Duties

• Design of spacecraft structures for manned and non-manned modules and satellites.
• Spacecraft mechanical design based on aerospace materials, encompassing tasks such as:
  • Definition and sizing of structural parts and interfaces via hand calculation or preliminary FEM analysis.
  • Selection of materials and associated surface treatments.
  • Definition of required tolerances.
  • Review of CAD models and drawings.
  • Finite Element Modelling using FEMAP, Patran, or Hypermesh pre and post-processors.
  • Structural static & normal mode analyses based on FEM (e.g., Nastran).
  • Supporting the spacecraft's mechanical development plan.
  • Reporting, including Design and Analysis reports, and support for design, development, and mechanical testing instrumentation plans.
• Occasionally, detailed verification through structural analysis (static, dynamic, fatigue, and fracture mechanics) using hand calculation or FEM, and support for static and dynamic testing preparation, attendance, and results evaluation.

Skills, Experience & Qualifications

The following are considered essential for this position:

• Strong Mechanical Engineering Knowledge.
• Knowledge of metallic and non-metallic technologies for materials and processes.
• Familiarity with aerospace design and analysis methodologies and associated manuals (e.g., Bruhn, Roarks) applicable to mechanical product design, development, and verification.
• Proficiency with CAD tools (e.g., CATIA) and understanding of manufacturing processes and capabilities.
• Ability to read and interpret manufacturing drawings.
• Full comprehensive capability with Windows Office package.
• Knowledge of Nastran solver.
• Experience with a FEM pre-post processor (Hyperworks, Femap, Patran).

Additional assets include competencies in using Matlab, Mathcad, Simulink, or equivalent, a Master Degree in Aerospace, Aeronautical, or Mechanical Engineering, and previous experience in Structural, Mechanical, or Industrial Engineering focused on structures and mechanical systems. Very good knowledge of English (written and spoken) is required; French language knowledge is a plus.

Key skills/competency

• Mechanical Design
• Aerospace Materials
• FEM Analysis
• Structural Engineering
• CAD Tools (CATIA)
• Nastran
• Hyperworks
• Patran
• Manufacturing Processes
• Spacecraft Structures