Mechanical Engineer - Sustaining

Job Title:

Mechanical Engineer - Sustaining

Job Category:
Engineering

Time Type:
Full time

Minimum Clearance Required to Start:
None

Employee Type:
Regular

Percentage of

Travel Required:

Up to 25%

Type of Travel:
Continental US

CACI is looking for staff to join our Photonics team developing space-based laser communications technology. We are seeking a hands-on Sustaining Engineer to bridge the gap between design and production, supporting our complex optomechanical and electromechanical systems. In this role, you will diagnose issues, drive root cause investigations, and partner with manufacturing and suppliers to continuously improve quality, yield, and manufacturability.

You will also execute design verification and environmental testing, and provide engineering support as new products transition into full-scale production. This is an excellent opportunity for an engineer who thrives on solving multidisciplinary problems and wants hands-on ownership of technical issues and process improvements in a design through production environment.

• Diagnose and resolve complex issues spanning optics, mechanics, electronics, and control systems, encountered during build, test, and integration.
• Lead root cause analysis (RCA) and corrective action (CAPA) efforts for performance deviations, test failures, and non-conformances identified in production.

• Collaborate with manufacturing teams to address yield issues, improve assembly processes, and implement design-for-manufacturing enhancements.
• Work directly with suppliers to address fabrication issues and yield improvements

• Support and execute product acceptance and environmental testing (including vibration, shock, thermal, etc.).
• Support closure of design verification activities.
• Contribute to continuous improvement of design, test, and build processes

• Manage engineering change orders (ECOs) to update designs, drawings, and documentation.
• Present failure analysis and proposed design changes to multidiscipline design and manufacturing teams.
• Create and edit procedures and test reports.

• B.S. or M.S. in Mechanical Engineering.
• Must be a US Citizen.
• 5+ years of industry experience in mechanical design, analysis, and testing.
• Demonstrated experience creating and releasing complex mechanical models, drawings, and assemblies.
• Strong proficiency with Solid Works and PDM/PLM systems. Knowledge of GD&T (ASME Y14.5) and mechanical drafting standards.
• Experience working with Microsoft Office tools (Word, PowerPoint, Excel).
• Strong written, verbal, and visual communication skills.
• A self-starter with excellent problem-solving skills who takes ownership of assigned tasks and drives them to completion.
• Comfortable working cross-functionally and reaching out across departments to resolve issues
• Ability to work in an environment needing to balance multiple priorities, and move fluidly between big-picture strategy and detailed execution
• Strong attention to detail and a collaborative, can-do attitude
• 25% travel within the U.S. may be required.

• Experience with aerospace, defense, or other high-reliability industries.
• Background in optomechanical systems, precision structures, or high-stability mechanical assemblies.
• Experience with gimbal systems or other precision motion control mechanisms, including design, integration, and optimization for applications in optical systems or robotics.
• Familiarity with material behavior in space environments (e.g., CTE matching, thermal gradients, out gassing)
• Knowledge of Design for Manufacturing (DFM) and Design Failure Mode and Effects Analysis (DFMEA)…