Professional Resume Template for
Senior Aircraft Mechanical Design Engineer
Marcus G. Sterling
Wichita, KS
(316) 555-0174
marcus.sterling@email.com
linkedin.com/in/marcus-sterling-aerospace | github.com/marcussterling | marcussterling-design.com
Professional Summary
Methodical Senior Aircraft Mechanical Design Engineer with 10 years of experience designing primary fuselage structures and mechanical routings. Proficient in CATIA V5/V6, Siemens NX, and ASME Y14.5 GD&T standards. Designed and certified 4 major airframe assemblies, reducing structural weight by 8.5% and saving $1.2M in raw materials. Collaborates with stress and manufacturing teams to optimize designs for DFM/DFA and ensure FAA Part 25 compliance. Skilled in managing change orders and Material Review Board dispositions via Teamcenter.
Work Experience
Senior Aircraft Mechanical Design Engineer — Spirit AeroSystems
Wichita, KS | January 2022 – Present
- Led a design team of 5 engineers to develop mid-fuselage structural assemblies in CATIA V6, reducing overall airframe weight by 6.8% and saving $450,000 in material costs.
- Authored 120+ Engineering Change Orders (ECOs) and resolved manufacturing discrepancies using Teamcenter, reducing assembly line rework by 18% over a 12-month period.
- Coordinated with stress and aeroelasticity groups to perform tolerance stack-up analyses, securing FAA Part 25 airworthiness certification for 3 flight test aircraft.
- Redesigned environmental control system ducting bracket attachments using composite materials, eliminating 15 vibration fatigue points and cutting assembly times by 22%.
Aircraft Mechanical Design Engineer — Textron Aviation
Wichita, KS | June 2016 – December 2021
- Designed primary wing ribs and spars for business jet structures using Siemens NX, contributing to a 4.2% reduction in fuel consumption through structural optimization.
- Conducted finite element analysis (FEA) using MSC Nastran and Patran to validate structural load paths, accelerating the preliminary design review phase by 14 days.
- Dispositioned 95+ Material Review Board (MRB) non-conformances on the production line, maintaining zero-defect tolerances and preventing assembly schedule delays.
- Optimized design layouts for landing gear attachment fittings using design-for-manufacturing (DFM) rules, reducing machining scrap by 25% and unit cost by $18,000 annually.
Education
Bachelor of Science in Aerospace Engineering
Wichita State University · Wichita, KS · 2016
Skills
CATIA V5/V6, Siemens NX, SolidWorks, ASME Y14.5 GD&T, Finite Element Analysis (FEA), MSC Nastran, MSC Patran, Ansys, Tolerance Stack-up Analysis, Aerospace Materials, Composite Laminate Design, Structural Integration, Mechanical Systems Routing, Teamcenter PLM, Enovia, Design for Manufacturing (DFM/DFA), FAA Part 23/25 Compliance, Material Review Board (MRB), Root Cause Analysis
Projects
Composite Wing Spar Redesign
Role: Lead Structural Design Engineer
Tools: CATIA V6, MSC Nastran, Teamcenter
Led the structural redesign of the wing spar to transition from aluminum to carbon fiber composite, reducing total assembly weight by 11.5% while maintaining a margin of safety greater than 0.15.
Hydraulic System Routing Optimization
Role: Systems Integration Engineer
Tools: Siemens NX, Ansys, Teamcenter
Redesigned the hydraulic system lines and brackets in the main wheel well area, resolving 32 spatial interferences and reducing maintenance installation time by 25%.
Certifications
- ASME Geometric Dimensioning and Tolerancing Professional (GDTP) - Senior Level (2021)
- Certified Systems Engineering Professional (CSEP) - INCOSE (2023)
- Certified Professional in CATIA V5 (Part Design & Assembly) (2018)
- Licensed Professional Engineer (PE) - Kansas State Board (2020)
Additional information
- Languages: English (Native), French (Conversational)
- Volunteer Work: Engineering mentor for local high school rocketry club (2018-present)
- Availability: 4 weeks notice
Job Market Insights
Market data and opportunities for
Senior Aircraft Mechanical Design Engineer
Job Market Insights
$115,000
-
$170,000
Avg:
$140,000
Growth Outlook:
Demand for Senior Aircraft Mechanical Design Engineers in the United States is driven by fleet modernization, defense aviation contracts, and the expansion of Advanced Air Mobility (eVTOL) systems. Aerospace firms are investing in lightweight composite structures and hybrid propulsion integrations to meet fuel efficiency goals. While automation optimizes routine drafting, senior design engineers are essential for complex systems integration, safety-critical stress analysis, and FAA certification compliance. Opportunities are projected to grow by 6% over the next decade.
6% growth over 10 years
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