Mechanical Engineer (Mechanisms)

Terrafugia is a fast-paced, energetic company that is developing the world’s first practical flying car. We are currently looking for a world-class Mechanical Engineer (Mechanisms) to join our vehicle development team. Candidates should be self-starters who bring positive attitude, integrity, and enthusiasm to our team as we transform personal transportation.


Key Responsibilities and Activities

  • Design, analysis, and system integration of the Transition® throttle and gear selection controls, including:
    • Combining mechanical and throttle-by-wire engine control mechanisms
    • Developing the gear selection mechanism to interface with the hybrid powertrain
    • Defining mechanism degrees of freedom, latching states, and sensor interfaces
    • Supporting sensor selection/integration for sensing commanded vehicle state
    • Material selection and mechanism designs for durability, low weight, and simplicity
    • Integration of the throttle and gear selection mechanisms with operator ergonomics
  • Participate as a key player in the design-build-test process for the Transition®, including conceptual, preliminary and detailed design, requirements definition, design reviews, prototyping, and testing
  • Coordinate and communicate effectively with other engineers, technical personnel, management, and external suppliers
  • Provide CAD work in support of design activities, direct drafting and product definition staff in the application of manufacturing drawing best practices, and define appropriate GD&T
  • Perform analyses, via hand calculations, kinematic simulations, and FEA, to validate designs
  • Support and participate in testing activities – component, drive, and/or flight – as needed, including test plan creation, data analysis, and test report generation and documentation
  • Support the Certification Director with compliance and certification activities including design, test, and analysis documentation, internal and external audits, and other activities as needed

Required Skills and Experience

  • Bachelor’s degree in Mechanical or Aerospace Engineering and 5+ years technical work experience, or;
  • Master’s degree in Mechanical or Aerospace Engineering and 3+ years technical work experience
  • Advanced SolidWorks experience – including SolidWorks Motion tool
  • Demonstrated experience designing robust, lightweight mechanisms for vehicles including operator controls
  • Expertise performing static and kinematic analyses for mechanical systems
  • Experience with finite element analysis in SolidWorks Simulation or an equivalent embedded FEA tool
  • Proven definition or production of manufacturing drawings including selection of dimension tolerances
  • Familiarity with material selection to meet strength, weight, durability, and cost targets
  • Proven experience with rapid design cycles: taking a design from concept through detailed design, build and test
  • Outstanding organization, analytical, and problem solving skills
  • Excellent written, verbal and presentation communication skills
  • Familiarity with basic shop tools (hand, power, mill, lathe, etc.)

Desired Skills and Experience

  • Hands-on experience installing automotive/aircraft throttle mechanisms, gear selectors, or propeller controls
  • Proven ability to select appropriate bearing types/sizes, implement latches, and design linkages
  • Familiarity integrating Hall Effect sensors, proximity or contact switches to sense mechanism state (position)
  • Formal training and professional experience with Geometric Dimensioning and Tolerancing (GD&T)
  • Background in designing with aerospace grade materials including fiber reinforced composites
  • Exposure to ANSYS Workbench, FEMAP/NASTRAN or any similar sophistication FEA software
  • Familiarity with MSC Adams or similar sophistication rigid-body kinematics simulation software
  • Exposure to low or medium volume production environments, particularly in automotive or aerospace industry
  • Familiarity with 49 CFR 571 regulations
  • Familiarity with ASTM F2245 regulations


Terrafugia provides equal employment opportunities (EEO) to all employees and applicants for employment without regard to race, color, religion, gender, sexual orientation, gender identity or expression, national origin, age, genetic information, disability, ancestry, religion or veteran status, or any other status protected under applicable federal, state or local law.

  • Accepted file types: pdf, doc, docx, txt, rtf.
  • Accepted file types: pdf, doc, docx, txt, rtf.
  • Accepted file types: pdf, doc, docx, txt, rtf.