Senior Design Engineer (Aerospace & Defense Hardware)

SENIOR DESIGN ENGINEER (AEROSPACE & DEFENSE HARDWARE) Freeform builds AI-native manufacturing systems that unify software, hardware, and physics to produce industrial-scale parts at the speed of human ideation. By treating manufacturing as a single integrated system, we unlock a new era of innovation where complex hardware is designed, built, and scaled without limits. Freeform is hiring a Senior Design Engineer focused on aerospace & defense hardware to sit at the intersection of advanced part design and additive manufacturing.

This is a deeply technical senior engineering role responsible for rethinking how aerospace and defense hardware is conceived, designed, and produced - not just adapting existing parts for a new process, but fundamentally reimagining what's possible when legacy design constraints no longer apply. You will own complex design challenges end-to-end, working hands-on with some of the most complex hardware in the industry, and serve as a technical authority on where Freeform's platform unlocks performance regimes, architectures, and geometries that were previously impractical or impossible. The ideal candidate is a highly experienced mechanical or aerospace engineer with deep intuition for part design, a genuine passion for pushing the boundaries of what hardware can do, and a track record of leading technical work on complex hardware programs.

They understand aerospace and defense systems at a component and systems level, can independently drive and mentor others on manufacturability, materials, and performance tradeoffs, and are excited by the creative challenge of designing parts from first principles. The core draw of this role is the engineering itself - though this person will also engage directly with some of the most sophisticated frontier companies in the aerospace and defense industr ies .

Responsibilities

: Drive part design and redesign across a broad range of aerospace and defense hardware, including: Propulsion systems Heat exchangers and thermal management hardware Valves and fluid systems Turbomachinery components Combustion devices Lightweight structural components and assemblies Develop and own deep component-level understanding of

Requirements

, performance drivers, and system constraints within aerospace and defense programs Lead first-principles part redesigns, identifying where additive manufacturing enables new geometries, consolidated assemblies, improved performance, or reduced cost and lead time Define and evaluate design concepts with expert command of materials, tolerances, thermal and structural behavior, and production considerations Serve as a senior technical resource - independently resolving advanced questions related to design tradeoffs, process capabilities, qualification pathways, and production scalability, and helping guide less experienced engineers Partner closely with internal engineering and operations teams to drive feasibility, refine concepts, and own execution outcomes Lead technical engagements with customer engineering teams to understand application

, present design solutions, and establish deep technical credibility at a senior level Identify, scope, and champion new application spaces where Freeform's technology can deliver step-change improvements over conventional manufacturing Shape Freeform's product, process, and technology roadmap through field-informed technical leadership and strategic input Basic

Qualifications

: Bachelor's degree in mechanical or aerospace engineering 5+ years of experience in a hands-on engineering role within aerospace, defense, or a closely related high-performance industry Demonstrated ability to lead complex hardware programs from concept through qualification and production Experience designing or analyzing propulsion systems, thermal systems, fluid systems, turbomachinery, or high-performance structural components Deep systems-level understanding of complex mechanical hardware and how components function within la