Principal Mechanical Engineer

CHAOS Industries is redefining modern defense with omniscient systems purpose-built for today’s realities. Designed and built by top U.S. military veterans and Silicon Valley innovators, CHAOS Industries’ products are powered by Coherent Distributed Networks (CDN™), empowering warfighters, commercial air operators, and border protection teams to act faster, adapt rapidly, and stay ahead of evolving threats. In a world where technological threats move at unprecedented speed, CHAOS Industries delivers advanced sensing and detection solutions that give the ultimate advantage: time.

Role Overview: CHAOS is seeking a Principal Mechanical Engineer to provide high‑value, hands‑on mechanical expertise for the integration of ruggedized electronics, effectors, and mission‑critical hardware into ground‑ and sea‑mobile platforms for aerospace and defense applications. In this role, you will own and lead the design for mechanical integration of military electronics and effector systems with critical platform structures and mechanisms. Design challenges may range from compact electronics enclosures to larger structural or mechanism assemblies, depending on platform and mission requirements.

• Provide technical leadership and hands‑on prototyping and mechanical integration of mission systems: electronics, enclosures, effectors, launchers, mechanisms, and support equipment into ground‑ and sea‑mobile platforms
• Architect and design mechanical structures, frames, mounts, enclosures, and mechanisms subject to shock, vibration, thermal, and environmental constraints
• Develop and maintain 3D CAD models, assemblies, and interface control documentation (ICDs) to support multi‑disciplinary system integration
• Perform first‑order structural and thermal analyses and requirements allocations to ensure compliance with customer requirements and applicable military standards
• Lead system‑level integration, qualification, and acceptance activities, including oversight of installation, alignment, and fit‑check efforts
• Serve as a primary technical hardware interface with customers, platform providers, suppliers, and manufacturing partners. Perform make/buy assessments
• Support production transition, configuration control, and fielded system sustainment, including investigation and resolution of integration issues

• Bachelor’s degree in Mechanical Engineering or a related discipline
• 8+ years of progressively responsible experience in platform‑level mechanical design and system integration for aerospace and defense applications
• Proven experience integrating mechanical subsystems and mission systems into vehicles, mobile platforms, or fixed installations
• Strong proficiency with CAD tools (e.g., Solid Works or equivalent) for large assemblies and top‑down design
• Solid understanding of mechanical interfaces, tolerancing, alignment, installation practices, and interface control documents (ICDs)
• Familiarity with structural analysis methods (hand calculations, FEA)
• Familiarity with ruggedized military hardware and environmental qualification considerations
• Experience interpreting and applying military standards, such as MIL‑STD‑810 and related platform qualification requirements
• Demonstrated ability to lead technical decisions and resolve complex, cross‑disciplinary integration challenges
• Strong communication skills and ability to operate effectively in multi‑project development environments
• Ability to obtain and maintain a U.S. security clearance

• Master’s degree in Mechanical Engineering or a related field
• Prior experience serving as a mechanical technical authority on a program
• Experience with mechanisms and actuation systems, including linkages, bearings, motors, hydraulics, and pneumatics, gimbals, or rotary joints
• Experience with system‑level requirements allocation
• Familiarity with vehicle integration constraints, including shock, vibration, transport, and operational loads
• Experience with at least one commercial FEA or multiphysics simulation package (NASTRAN, ABAQUS, ANSYS, CFD codes, COMSOL, etc.)
• Knowledge of manufacturing and assembly processes for mobile or deployable mechanical structures and mechanisms
• Experienc…