The Senior Mechanical Engineer will lead the design, development, and rapid integration of mechanical systems supporting advanced defense applications, including unmanned systems, sensor payloads, and mission-critical hardware. This role requires a hands-on engineer capable of moving quickly from concept to prototype to fieldable system, often under compressed timelines and evolving requirements.
The ideal candidate thrives in fast-paced environments, balances analytical rigor with practical execution, and is comfortable working across multidisciplinary teams to deliver integrated solutions.
Essential Job Functions:
• Lead mechanical design of complex assemblies, including enclosures, mounting structures, thermal solutions, and structural components for defense systems
• Develop designs from concept through detailed design, prototype fabrication, and test
• Perform trade studies to balance weight, strength, thermal performance, manufacturability, and cost
• Create and maintain 3D CAD models, drawings, and technical data packages (TDPs)
• Drive rapid build-test-iterate cycles with a focus on speed and performance
• Support hands-on integration of hardware into platforms (e.g., UAVs, ground systems, sensor pods)
• Work closely with electrical, systems, and software engineers to ensure seamless integration
• Troubleshoot mechanical and system-level issues during lab and field testing
• Conduct structural, thermal, and vibration analyses (FEA/hand calculations)
• Support environmental qualification aligned with standards such as MIL-STD-810
• Develop and execute test plans to validate mechanical performance and durability
• Interface with fabrication resources (machine shops, additive manufacturing, vendors)
• Ensure designs are manufacturable and support low-rate initial production (LRIP)
• Support design for manufacturability (DFM) and design for assembly (DFA)
• Support program milestones including SRR, PDR, CDR, and test readiness reviews
• Provide technical leadership within Integrated Product Teams (IPTs)
• Estimate effort, identify risks, and propose mitigation strategies
• Contribute to proposal efforts and technical planning for new programs
Required Qualifications
• Bachelor’s degree in Mechanical Engineering or related field (Master’s preferred)
• 8+ years of experience in mechanical design, preferably in aerospace or defense
• Strong proficiency in CAD tools (e.g., SolidWorks)
• Experience with rapid prototyping methods (CNC, 3D printing, sheet metal, composites)
• Familiarity with environmental and durability requirements for defense systems
• Ability to work hands-on in a lab or integration environment
• U.S. Citizenship and ability to obtain/hold a security clearance
Preferred Qualifications
• Experience with UAVs, missiles, sensor systems, or payload integration
• Knowledge of thermal management for electronics and high-power systems
• Experience designing for harsh environments (vibration, shock, temperature extremes)
• Familiarity with MIL standards (e.g., MIL-STD-810, MIL-STD-461)
• Experience supporting live testing or operational deployments
• Background in lightweight structures, composites, or sealed enclosures
Work Environment
• Mix of office, lab, and field test environments
• Frequent hands-on interaction with integrated systems and hardware
•Occasional travel for integration and field testing
Physical Requirement:
Schedule: