Mechanical Engineer

Mechanical Engineer

Join a multidisciplinary engineering team designing, fabricating, testing, and deploying prototypes for counterunmanned aircraft systems (cUAS) technology. As a Mechanical Engineer, you will own mechanical designs that directly contribute to next-generation airspace defense systems, taking concepts from initial idea through production release. You will collaborate closely with electrical, software, systems, manufacturing, and product teams to deliver rugged, reliable hardware solutions that operate in demanding real-world environments.

Responsibilities

• Design and develop mechanical components, assemblies, and enclosures for advanced airspace defense systems.
• Drive product development activities from concept generation through testing, validation, and manufacturing release.
• Create detailed 3D CAD models, drawings, and design documentation using tools such as Solid Works, Fusion 360, AutoCAD, or similar platforms.
• Design a wide range of hardware including sheet metal components, welded structures, machined parts, injection molded components, and environmental enclosures.
• Build, assemble, and evaluate prototype hardware to validate design concepts and overall system performance.
• Develop and execute test plans to assess functionality, durability, and environmental reliability of mechanical designs.
• Collaborate cross-functionally with electrical engineers, systems engineers, product managers, manufacturing partners, and field teams to ensure cohesive system integration.
• Support system integration efforts and actively contribute to design reviews throughout the product lifecycle.
• Identify technical risks and implement creative, practical solutions to complex engineering challenges.
• Maintain thorough documentation, specifications, and engineering change records to ensure traceability and quality.
• Contribute to continuous improvement initiatives focused on product quality, manufacturability, and cost optimization.
• Allocate time across key activities, including approximately 30% CAD design and documentation, 30% cross-functional collaboration and engineering reviews, 30% hands-on prototyping, fabrication, testing, and validation, and 10% rapid-response engineering support and problem solving.

Essential Skills

• Bachelor's degree in Mechanical Engineering or a closely related engineering discipline.
• 0-3 years of professional mechanical engineering experience.
• Proficiency with CAD software such as Solid Works, AutoCAD, Fusion 360, or similar platforms.
• Experience creating engineering drawings and design documentation suitable for manufacturing and production.
• Ability to work with fabrication and prototyping processes, including basic hands-on build and test activities.
• Eligibility to obtain a US Secret Clearance.
• Ability to travel up to 10% of the time as project needs require.
• Strong analytical and problem-solving skills applied to mechanical design and system performance.
• Effective communication skills for collaborating with cross-functional engineering and product teams.
• Attention to detail and commitment to maintaining accurate technical documentation and records.

Additional Skills & Qualifications

• Experience designing and releasing mechanical products into production environments.
• Hands-on prototyping experience using fabrication tools, machine shop equipment, or 3D printers.
• Experience with sheet metal design, weldments, machined components, injection molded plastics, or ruggedized mechanical enclosures.
• Familiarity with embedded systems, microcontrollers, or electromechanical systems and their mechanical integration.
• Experience designing hardware for harsh environmental conditions, including outdoor or industrial use.
• Knowledge of shock, vibration, thermal management, EMI/EMC, or environmental sealing considerations in mechanical design.
• Experience working with military, aerospace, defense, industrial, robotics, or outdoor hardware systems.
• Familiarity with MILSTDs and environmental qualification testing processes.
• Experience with FEA, CFD, or other simulation tools to analyze structural and thermal performance.
• Understanding of GD&T (Geometric Dimensioning and Tolerancing) for precise manufacturing specifications.
• Experience in new product development, including iterative design, prototyping, and validation cycles.
• Ability to identify design tradeoffs related to cost, manufacturability, and reliability, and to optimize accordingly.

Work Environment

This role is based in Sterling, VA, with a hybrid schedule that includes four days per week…