Mechanical Engineer

Job Title: Mechanical Engineer

Location: Germantown, Maryland Onsite

• Lead end-to-end hardware development for AERO mobile solution, from conceptual design through production and in-service operation
• Interact with various stakeholders to ensure project alignment and success
• Own design, hardware verification, and qualification testing
• Support production ramp-up and field deployment activities
• 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, conduct tolerance stack-up analyses, and ensure manufacturability and performance
• Drive design for manufacturability (DFM) by simplifying designs, reducing parts, and implementing 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 continuously improving reliability and performance

• 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
• 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 high-reliability environments
• Proficiency in CAD tools (e.g., Creo, Solid Works) and engineering analysis methods including FEA and CFD
• Experience performing hand calculations and validating designs through analytical and simulation approaches
• Knowledge of electronic board assembly design, including mechanical integration, mounting strategies, and thermal management
• 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 DFM and DFA principles
• Familiarity with FAA certification processes and regulatory standards (e.g., DO-160, FARs)
• Experience conducting environmental and performance testing, including validation and verification methods
• Strong problem-solving skills in fast-paced, iterative development environments
• Excellent communication and collaboration skills for multidisciplinary team work
• Ability to manage multiple priorities and product development timelines
• 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 supporting high-rate production environments or in-house manufacturing lines
• Knowledge of supply chain, production processes, and lifecycle management
• Advanced degree in Mechanical Engineering or related field

We offer eligible employees health and welfare benefits coverage options including medical, dental, vision, spending accounts, life insurance, voluntary plans, as well as participation in a 401(k) plan.

System One is an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex (including pregnancy, childbirth, or related medical conditions), sexual orientation, gender identity, age, national origin, disability, family care or medical leave status, genetic information, veteran status, marital status, or any other characteristic protected by applicable federal, state, or local law.