Sr Mechanical Engineer

About the role

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

• Prolonged periods sitting at a desk and working on a computer.
• Occasional visits to engineering or manufacturing environments as required.
• Must be able to lift up to 15 pounds at times.

Schedule

• M-F, 8-5 -Central Time. Ability to work after hours during the week and weekends, as the workload requires.
• Note: The duties and responsibilities described on this document are not necessarily a comprehensive list and additional tasks may be assigned to the teammate from time to time; and the scope of the job may change as necessitated by business demands.