Senior Mechanical Design Engineer – Aerospace Hardware

Senior Mechanical Design Engineer – Aerospace Hardware

Echo Star builds solutions that help families and communities stay connected. We'll launch your career and empower you to change lives.

Our brands include Boost Mobile, DISH TV, Gen Mobile, Hughes and Sling TV. We serve millions of customers with offerings ranging from satellite to streaming services and global to personal networking solutions.

Echo Star has an exciting opportunity in our Hughes Network Systems division for a dynamic and experienced Senior Mechanical Design Engineer – Aerospace Hardware. This position will be located at our headquarters in Germantown, MD.

Key Responsibilities:

• Lead end-to-end hardware development for AERO mobile solution, from conceptual design through production and in-service operation
• Interact with various stakeholders
• Own design, HW verification and qualification testing, production ramp up and field deployment
• Define design criteria, collaborate cross-functionally to refine requirements, and drive system-level optimization
• Perform engineering analyses using hand calculations, FEA, CFD, and CAD tools in a fast-paced, iterative environment
• Rapidly develop and refine design solutions to support system trade studies and influence overall product direction
• Lead design reviews and partner with internal certification team to qualify components and systems
• Develop detailed production drawings using GD&T and conduct tolerance stack-up analyses to ensure manufacturability and performance
• Drive design for manufacturability (DFM), simplifying designs, reducing part and process count, and implementing robust error-proofing strategies
• Establish and optimize the product lifecycle from supply chain through final integration, balancing cost, quality, and complexity
• Collaborate with cross-functional partners to design and implement efficient in-house production capabilities
• Plan and execute environmental and performance testing to validate designs and ensure compliance with requirements
• Own product delivery timelines across all phases—concept, design, build, and service—while driving continuous improvements in reliability and performance

Basic Requirements:

• Bachelor's degree in mechanical engineering, aerospace engineering, or related technical field
• 6+ years of experience with mechanical/electromechanical design, analysis, testing, and/or manufacturing

Preferred Qualifications:

• Strong foundation in mechanical engineering principles, including statics, dynamics, thermodynamics, and materials
• Proven experience in hardware design and development for complex systems, preferably in aerospace or similar high-reliability environments
• Proficiency in CAD tools (e.g., Creo, Solidworks etc.) and engineering analysis methods including FEA and CFD (e.g. Flotherm, FloEFD etc.)
• Experience performing hand calculations and validating designs through analytical and simulation approaches
• Experience with electronic board assembly design, including mechanical integration, mounting strategies, and thermal management solutions
• Working knowledge of electronics design across chip-level, package-level, and board-level integration
• Deep understanding of GD&T and tolerance stack-up analysis for production-ready designs
• Knowledge of design for manufacturability (DFM) and design for assembly (DFA) principles
• Familiarity with FAA certification processes and working with regulatory standards (e.g., DO-160, FARs)
• Experience conducting environmental and performance testing, including validation and verification methods
• Strong problem-solving skills with the ability to work effectively in fast-paced, iterative development environments
• Excellent communication and collaboration skills, with experience working across multidisciplinary teams (electrical, RF, EMC, manufacturing)
• Ability to manage multiple priorities and own product development timelines from concept through production
• Strong attention to detail, with a focus on reliability, performance, and continuous improvement
• Experience with aircraft systems or avionics hardware integration
• Familiarity with RF, EMI/EMC considerations in hardware design
• Experience…