Mechanical Engineer

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Booz Allen Hamilton is offering this role to an innovative Mechanical Engineer with experience in the aerospace and defense industry. In this position, you will apply advanced engineering skills, extensive technical expertise, and full industry knowledge to identify solutions for flight platforms, oversee the design of flight hardware, and interface with vendors and stakeholders to ensure mechanical requirements are met. This line of effort will involve collaboration with systems and electrical engineers to complete design and technical analysis of ruggedized solutions.

You will work without considerable direction, and you will mentor and supervise team members.

• 5+ years of experience in hardware design, analysis, and prototyping, including design for manufacturing and assembly (DFMA)
• Experience with 3D modeling in Solid Works
• Experience leading a functional task team and collaborating with an integrated product team and partnering engineering teams, including technical and non-technical teammates
• Experience with multiple manufacturing technologies and approaches, including traditional subtractive manufacturing techniques and additive techniques
• Experience with product design for manufacturability, reliability, and maintainability
• Experience with product ruggedization for extreme environments
• Knowledge of engineering and physics principles as they apply to hardware design and product development, including material science, geometric dimensioning and tolerancing, mechanics of materials, basic physics, statics, kinematics, and thermodynamics
• Knowledge of thermal mitigation techniques and analysis methods for packaged electronics
• Ability to obtain a Secret clearance
• Bachelor’s degree in mechanical engineering or aerospace engineering and 5+ years of experience with design for manufacturability (DFM), fabrication, assembly, and integration of electromechanical prototype hardware, or Master’s degree in mechanical engineering or aerospace engineering and 3+ years of experience with DFM, fabrication, assembly, and integration of electromechanical prototype hardware

• Experience developing Technical Data Packages (TDP) for flight hardware
• Experience analyzing and translating system requirements into design
• Experience with airworthiness requirements and testing
• Experience with MIL-STD-810 testing, including shock, vibration, and temperature
• Experience with lab-based developmental testing and test data acquisition
• Experience leading mechanical design reviews, such as PDR, CDR, IRR, or TRR
• Experience with ANSYS Finite Element Analysis (FEA) and Computational Fluid Dynamics (CFD)
• Knowledge of Size, Weight, Power and Cooling (SWaP‑C) requirements and design
• TS/SCI clearance
• 3D Modeling, Geometric Dimensioning and Tolerancing (GD&T), FEA, or CAD Certification

Applicants selected will be subject to a security investigation and may need to meet eligibility requirements for access to classified information.

At Booz Allen, we celebrate your contributions, provide you with opportunities and choices, and support your total well‑being. Our offerings include health, life, disability, financial, and retirement benefits, as well as paid leave, professional development, tuition assistance, work‑life programs, and dependent care. Our recognition awards program acknowledges employees for exceptional performance and superior demonstration of our values. Full‑time and part‑time employees working at least twenty hours a week on a regular basis are eligible to participate in Booz Allen’s benefit programs.

Individuals that do not meet the threshold are only eligible for select offerings, not inclusive of health benefits. We encourage you to learn more about our total benefits by visiting the Resource page on our Careers site and reviewing Our Employee Benefits page.

Salary at Booz Allen is…