Principal Mechanical Engineer

• Lead products through the full lifecycle; from concept development to integration, testing, and production release.
• Perform mechanical engineering activities for rugged subsystems and complex PCB assemblies, including mechanical packaging, connector selection, cable and label design, prototype inspection and assembly, environmental testing, and supporting hardware documentation procurement
• Collaborate closely with cross‑functional partners such as Hardware/Electrical Engineering, Manufacturing, Quality Engineering, and Procurement
• Develop and maintain Bills of Material (BOMs/PLs) to support accurate configuration and production control
• Draft, submit, and manage Engineering Change Requests (ECRs) and Engineering Change Orders (ECOs)
• Conceptualize, design, analyze, and document mechanical hardware and systems intended for rugged military and space environments
• Conduct thermal and structural analysis and/or simulations to ensure robust mechanical and environmental performance
• Design complex fixtures to support product testing and advanced manufacturing processes
• Create detailed 3D models and engineering drawings
• Communicate design concepts and produce clear, high‑quality product documentation for diverse internal and external audiences
• Support environmental and functional design verification testing in accordance with MIL‑STD‑810 for severe operating conditions
• Provide hands‑on support during initial build validation of new designs, ensuring form, fit, and function are met
• Perform failure analysis of discrepant material in partnership with Manufacturing and Quality Engineering teams
• Develop test plans, inspection reports, and associated documentation in support of verification and validation activities
• Mentor and train junior engineers
• This role requires the ability to obtain and maintain a U.S. government security clearance; U.S. citizenship is required

• Bachelor's degree in mechanical or aerospace engineering
• Typically requires a minimum of 6 years of relevant mechanical engineering experience
• Familiarity with GD&T, ASME Y14.5, Y14.100
• Experience and understanding of PWA/CCA design and associated manufacturing processes
• Proven experience designing electronics packaging for severe environments, including compliance with MIL‑STD‑810
• Proficiency with 3D CAD software such as Solid Works or CREO
• Broad knowledge of both conventional and advanced manufacturing techniques, including machining and post‑processing for CCAs and metal components
• Strong foundational understanding of heat‑transfer design principles and dynamic system design for shock and random vibration environments
• Familiarity with configuration management and material control processes, including routers, work instructions, and related tools i.e. Agile, Oracle, EPDM
  Proficiency with standard engineering documentation and presentation tools
• This role requires the ability to obtain and maintain a U.S. government security clearance; U.S. citizenship is required

• Master's degree in mechanical or aerospace engineering
• Aerospace and Defense Industry experience
• Expertise with GD&T, ASME Y14.5, Y14.100
• Experience performing thermal analysis using tools such as 6
  
  Sigma, Celsius, SC Stream, or SC Flow
• Experience performing Structural analysis using tools such as Solid Works Simulation, Femap/NASTRAN)

Fulltime Equivalent Job Grade Salary Range for this position

• $87,100.00 - $ annual salary for in-office or hybrid employees in FL, GA, IN, AZ, AL, MD or TX, and all remote employees
• $97,600.00 - $ annual salary for in-office or hybrid employees in VA, CA, NH or MA
• $ - $ annual salary for in-office or hybrid employees in NJ

Mercury considers a variety of factors to determine individual…