Principal Mechanical Engineer – Phased Array Radar Systems

Principal Mechanical Engineer – Phased Array Radar Systems

Location:

Onsite / Hybrid – Richardson TX (DFW area)

Employment Type:

Full-Time

Clearance:
Ability to obtain to Secret clearance

We are seeking a Principal Mechanical Engineer to lead the mechanical design, system integration, and production manufacturing of phased‑array radar systems used in advanced defense and aerospace applications. This role owns the physical architecture of the radar subsystems and array, working closely with RF, electrical, thermal, manufacturing, and systems engineering teams to deliver ruggedized, high‑performance hardware from concept through deployment.

• Serve as Chief Engineer for all mechanical aspects of the radar and contribute as the technical authority for system integration requirements.
• Responsible for design release and sign‑off to production.
• Lead architecture discussions and decisions between teams.
• Document trade studies and analyses of cost/performance details.
• Structural design and analysis of integrated electromechanical system components at both prototype and mass manufacture scales.
• Integrated FEA analysis of components to meet thermal and mechanical requirements for both commercial and military specifications.
• Adaptation of RF and EE design requirements into CAD designs.
• Specification of cable assemblies, terminations, and compact routing.
• Design & detail of complex machine assembly methods.
• Management of varied manufacturing methods, including sheet metal, CNC, extrusion, brazing, welding, PCBA, glue‑up, assembly jigs, and test stands.
• System design across thermal, power, and mechanics to meet diverse engineering and business requirements.
• Manage vendor relations on sourced components and serve as technical authority on component specifications.
• Perform multi‑domain design studies across varied system configurations.
• Interface with manufacturing and assembly teams to coordinate responsibilities and handoffs.
• Design & test of high‑load thermal management and cooling systems.
• Integration of high‑voltage field power generators with human operators.
• Lifecycle design including operational and service aspects of the radar assembly, system components, and deployment equipment in varied environments.
• Maintain professional standards across teams and functions.
• Design release cycles, drawing packets, GD&T, DFM, ISO 9001, ISO‑MIL, AS9100, sourcing, manufacturing standards, etc.
• Perform design reviews and revision control.
• Support manufacturing across the company, providing DFM for prototyping, pilot, and production runs, both in‑house and with CM’s, serving engineering and business.
• Design for manufacturability and high‑reliability production.
• Support prototype builds and production scaling.
• Participate in failure analysis and corrective actions.

• Bachelor’s degree in Mechanical Engineering (Master’s preferred).
• 10+ years of experience in defense, aerospace, radar, or similar systems.
• Experience with phased‑array radar or related RF electromechanical hardware.
• Proficiency with CAD tools (Solid Works preferred), FEA simulation, and thermal models.
• Strong background in structural, thermal, and vibration analysis.
• Ability to obtain and maintain a U.S. security clearance.

• Experience with AESA radar systems and high‑power RF electronics.
• Experience with complex machine design and production life cycles.
• Rapid R&D prototyping methods and translation to scaled production processes in aerospace materials and tooling.
• Familiarity with RF materials and design rules for radomes, enclosures, and antennas.

Mid‑Senior level

Full‑time

Engineering and Information Technology