Sustainment Mechanical Engineer

Position Summary

The Sustainment Mechanical Engineer is responsible for the ongoing support, improvement, and reliability of released mechanical and electromechanical products throughout their production lifecycle. In this role, you will own mechanical design changes for fielded and in‑production systems, resolve quality and manufacturing issues, and ensure product performance, reliability, and compliance are maintained over time. You will apply strong analytical and design skills—including structural FEA, vibration and modal analysis, and heat transfer—to diagnose issues, implement corrective actions, and support continuous improvement.

This position requires hands‑on experience with injection‑molded components, cross‑functional collaboration, and rigorous document and configuration control within a PdM and PLM environment.

• Own mechanical sustainment activities for released products across production and fielded units
• Investigate and resolve quality, reliability, and manufacturing issues through structured root‑cause analysis
• Develop and implement engineering change orders (ECOs) and product updates while maintaining configuration control
• Perform structural FEA to assess design changes, fatigue, durability, and failure modes
• Conduct vibration and modal analysis to evaluate field failures, resonance issues, and environmental loading
• Perform thermal and heat transfer analysis to support corrective actions and design improvements
• Design and update injection‑molded plastic and machined components, ensuring tooling and production readiness
• Support production, suppliers, and contract manufacturers with design clarifications and corrective actions
• Collaborate with Quality, Manufacturing, Supply Chain, and Verification Test teams to drive issue resolution
• Support failure analysis activities, including test correlation and data review
• Ensure DFM/DFA and DFT best practices are applied to sustainment design changes
• Maintain accurate CAD models, drawings, specifications, and GD&T
• Own mechanical document control, including drawings, BOMs, change history, and release status in the PLM system
• Support production line issues, yield improvement, and cost‑reduction initiatives
• Assist in supplier change evaluations and part obsolescence mitigation
• Provide technical guidance to manufacturing and quality teams during audits and reviews

• BS or MS in Mechanical Engineering or related field
• 3+ years’ experience supporting production and fielded mechanical products
• Demonstrated expertise in structural FEA, vibration/modal analysis, and thermal analysis
• Proven experience with injection molding design, tooling changes, and production constraints
• Solid understanding of mechanical failure mechanisms, fatigue, wear, and environmental effects
• Proficiency in Solid Works, PDM, and PLM systems
• Experience with engineering change management and document/configuration control
• Familiarity with first article inspection (FAI), non‑conformance resolution, and corrective action processes
• Ability to work effectively across cross‑functional teams and external suppliers
• Strong attention to detail and documentation discipline

• Experience supporting high‑volume or regulated manufacturing environments
• Experience with cost‑reduction and value engineering initiatives
• Experience supporting products through long‑term lifecycle and end‑of‑life transitions

• Must be able to walk, stand, and navigate large indoor and outdoor facilities for extended periods of time.
• Ability to lift, carry, and move materials and equipment weighing up to 25 lbs on a regular basis.
• Use of personal protective equipment (PPE) may be required in designated areas or when performing specific tasks, in accordance with safety protocols and company policy.
• May be required to climb ladders, stoop, kneel, or crouch during inspections, maintenance walk‑throughs, or emergency response situations.
• Regular exposure to facility operations including noise, dust, temperature fluctuations, and industrial equipment.
• Occasional off‑hours or weekend work required for emergency facility…