Senior Mechanical Engineer (CAD, FEA/CFD, Thermal, DFM)

About the role We're building out ongoing mechanical engineering capacity and are looking for one senior engineer to work with us on a recurring part-time basis. Rather than a single deliverable, this is a continuing relationship: you'll pick up design, analysis, and documentation work as it comes, with roughly consistent weekly hours once we've settled into a rhythm. What you'll do Develop and revise 3D CAD models and assemblies for new and existing designs Run structural FEA (static, modal, fatigue as needed) to validate designs before fabrication Perform CFD and thermal/fluid analyses — flow, pressure drop, heat transfer, HVAC sizing Conduct design-for-manufacturing reviews and recommend changes that cut cost or scrap Produce production-ready 2D drawings with correct GD&T, tolerance stacks, and BOMs Interpret results into plain-language recommendations our team can act on Coordinate with fabrication and machining vendors on manufacturability questions Required qualifications 8+ years of professional mechanical design and analysis experience Expert proficiency in at least one major CAD platform (SolidWorks, Creo, Fusion 360, NX, or Inventor) Demonstrated FEA experience (ANSYS, Abaqus, SolidWorks Simulation, or equivalent) with an understanding of mesh quality, boundary conditions, and result validation CFD or thermal analysis experience (ANSYS Fluent, Star-CCM+, COMSOL, or similar) Strong command of ASME Y14.5 GD&T and drafting standards Practical DFM knowledge across machining, sheet metal, weldments, and injection molding Clear written English and the ability to explain analysis assumptions and limitations Preferred Licensed Professional Engineer (PE) or equivalent professional credential Experience stamping or reviewing drawings for regulatory or code compliance Familiarity with tolerance analysis tools and hand-calculation verification of simulation results Prior experience supporting a client team remotely on a recurring basis How we work Ongoing part-time engagement with a consistent weekly commitment Work is tracked and paid through Upwork Regular check-ins by video call, plus async updates between them All files, models, and analysis reports delivered in native and neutral formats (STEP, PDF) To apply Please include: Two or three examples of past work that show CAD, simulation, and drawing output (redact anything confidential) The CAD and simulation tools you use most, and roughly how long you've used each Your typical weekly availability and time zone A short paragraph on how you'd approach validating a design where simulation results and hand calculations disagree