Senior Mechanical Design Engineer (Multiple Tracks: Core Tech, Lethality, & DFM/DFA)

Job description

Job responsibilities

• Core Technology Products: Architect foundational hardware platforms spanning aircraft, missiles, maritime vessels, and ground systems.
• Lethality (Warhead Design): Design and mature advanced warheads, ordnance, and munitions systems. You will bridge mechanical engineering, dynamic modeling, energetic material packaging, safety constraints, and…
• Design for Excellence (DFM / DFA): Sit at the critical interface between initial CAD concepts and production reality.
• End-to-End Hardware Ownership: Own components and complex mechanical assemblies from requirements definition, hand calculations, and conceptual design through prototyping, testing, and volume manufacturing.
• Rigorous Mechanical Design: Create high-fidelity 3D models and fully defined 2D drawing packages in strict accordance with ASME Y14.5 (GD&T) standards.
• Multi-Discipline Engineering: Design parts across diverse fabrication processes—including precision 3/5-axis CNC machining, complex weldments, sheet metal, injection molding, composite layups, and structural adhesive…
• Analysis & Simulation: Apply first-principles engineering and FEA/hand calculations to validate structural, thermal, vibrational, and tolerance-stackup performance under harsh operational conditions.
• Design for Manufacturing & Assembly (DFM/DFA): Perform 1D/3D tolerance stacks, DFMEAs, and tool-access assessments early in development to de-risk production bottlenecks and scale throughput.

Job requirements

• Bachelor’s degree (or higher) in Mechanical Engineering, Aerospace Engineering, Manufacturing Engineering, or a related discipline.
• 7+ years of professional mechanical design experience taking physical hardware from initial concept through fabrication and functional test.
• High proficiency in parametric 3D CAD (SolidWorks, NX, or Creo) and modern PLM/PDM environments (e.g., Teamcenter).
• Working knowledge of engineering drawings and practical application of ASME Y14.5 GD&T and tolerance stack-up analysis.
• Demonstrated hands-on prototyping and fabrication skills with a track record of root-causing manufacturing and hardware defects.
• Strong foundation in engineering first principles (statics, dynamics, material selection, heat transfer, and structural mechanics).
• Clearance: Must be eligible to obtain and maintain a U.S. Security Clearance (Secret or Top Secret depending on division).
• Lethality Track: Experience with naval ordnance, warheads, energetic materials, DoD weapons safety boards, high-rate dynamic modeling, or live-fire arena testing.