Principal Mechanical Engineer - Structures

Karman Industries

Signal Hill, CA

Founded in 2024 and headquartered in Signal Hill, California, Karman Industries is at the forefront of revolutionizing industrial thermal energy. Our mission is to electrify global thermal systems across data centers, manufacturing, and energy industries. Karman is developing the revolutionary Heat Processing Unit (HPU) to reinvent thermal handling for giga-scale data centers & AI factories. The HPU is built around a supercritical CO2 chiller system utilizing a high-speed electrically driven turbomachinery core. Our system aims to reduce energy consumption in data center thermal management by greater than 25% and increase energy density by 10x.

At Karman Industries, we are committed to fostering a dynamic and inclusive work environment where innovation thrives. Our team is composed of passionate professionals dedicated to making a tangible impact on the future of industrial manufacturing. Join us in our mission to transform the industry and contribute to a more sustainable world.

Principal Structures Engineer

Karman Industries is seeking a highly motivated Principal Structures Engineer to own structural analysis and design for the skids, weldments, and lifting/transport hardware that carry our sCO2 turbomachinery systems into the field. The successful candidate will be the senior technical authority on structural integrity for Karman's product line, from global finite element models down to the hand calculations and code checks that substantiate them.

This role requires deep hands-on analysis skill combined with the judgment to set structural standards across a growing engineering org. You will build and run global FEM (GFEM) models of full skid assemblies, develop and maintain the Femap API tooling that scales that analysis, and close out structural risk on skid weldments, secondary structure, and rigging hardware from concept through fabrication. We are a team that values first-principles thinking, hands-on problem solving, and close cross-functional collaboration to deliver cohesive, high-performance systems.

Responsibilities:

Own structural analysis for skid weldments, secondary structure, and pressure-boundary supports across Karman's turbomachinery skids

Build, run, and maintain global finite element models (GFEM) of full skid assemblies in FEMAP/Nastran, including static, modal, and random vibration (PSD) analysis

Develop and extend Femap API macros and scripts to automate model setup, load application, and freebody force extraction across recurring analysis workflows

Perform and review hand calculations and closed-form checks (AISC 360, AWS D1.1, BTH-1, ASCE 7) to validate FEA results and support design decisions

Lead crane lift analysis and lifting lug/padeye design and certification, including multi-point lift geometry and safety factor stack-ups

Drive transport and shipping analysis for skid-mounted equipment, including MIL-STD-810G random vibration and FMCSA cargo securement compliance

Build and maintain engineering tools (Excel/VBA, Python) that scale structural analysis and reduce turnaround time across programs

Set and enforce structural analysis standards, calculation templates, and review processes across the engineering organization

Represent structures at Critical Design Reviews (CDRs) and produce clear, code-referenced documentation for internal and customer-facing review

Closely partner with fabrication, quality, and manufacturing to ensure weld joint design, NDT requirements, and structural details are manufacturable

Required Qualifications:

Bachelor's degree in mechanical, aerospace, civil/structural engineering or related discipline

8+ years of experience in structural analysis of weldments, skids, or built-up structures, with direct ownership of structural substantiation

Strong proficiency in FEMAP/Nastran, including global FEM (GFEM) build-up, boundary conditions, and modal/random vibration analysis

Hands-on experience with the Femap API for scripting and automating analysis workflows

Deep understanding of structural fundamentals, including materials, weld design, load path, and code-based analysis

Proficiency in Python and/or Excel/VBA for building internal engineering tools

Highly self-motivated, detail-oriented, and capable of managing multiple priorities with excellent communication skills

Desired Skills and Experience:

Master's or higher degree in mechanical, aerospace, or structural engineering

Working knowledge of AISC 360, AWS D1.1, BTH-1, and ASCE 7

Experience with lifting equipment design/certification and transportation/shipping analysis (MIL-STD-810G, FMCSA 49 CFR Part 393)

Familiarity with ANSYS MAPDL or other FEA solvers in addition to FEMAP/Nastran

Experience with pressure vessel or piping structural interfaces (ASME B31.3 or Section VIII)

Demonstrated ability to take structural designs from concept through analysis, test, and production release

Familiarity with fabrication and manufacturing environments, including weld processes and design for manufacturability

Compensation bands are determined by role, level, location, and alignment with market data. Individual level and base pay is determined on a case-by-case basis and may vary based on job-related skills, education, experience, technical capabilities and internal equity. In addition to base salary, for full-time hires, you may also be eligible for long-term incentives, in the form of stock options, and access to medical, vision & dental coverage as well as access to a 401(k) retirement plan.

Karman Industries is an Equal Opportunity Employer; employment with Karman Industries is governed on the basis of merit, competence and qualifications and will not be influenced in any manner by race, color, religion, gender, national origin/ethnicity, veteran status, disability status, age, sexual orientation, gender identity, marital status, mental or physical disability or any other legally protected status.

Direct applicants only — we are not working with outside recruiters or agencies for this role.