Mechanical Design Engineer

Mechanical Design Engineer

TSC is seeking a highly motivated and skilled Mechanical Design Engineer to support our customer in Washington, DC. The ideal candidate will be a hands‑on engineer with a strong background in mechanical systems, assemblies, and product development. This role involves full‑lifecycle engineering, from concept development and design to prototyping, testing, integration, maintenance and sustainment of advanced systems and hardware for communication systems.

You will work onsite alongside other engineers and professionals at various customer locations, collaborating with multidisciplinary teams in a fast‑paced and challenging environment.

• Mechanical System Design & Development
  • Design and develop robust and reliable mechanical and electromechanical systems, assemblies, and components.
  • Analyze system requirements and translate them into detailed mechanical design specifications.
  • Create 3D CAD models, engineering drawings and manufacturing documentation.
  • Perform tolerance analysis, material selection and design‑for‑manufacturability (DFM) assessments.
  • Create and maintain detailed documentation for all stages of the design process.
• Prototyping, Testing & Troubleshooting
  • Develop and execute comprehensive test plans for mechanical systems and assemblies.
  • Build, assemble, and evaluate prototypes to validate designs and performance requirements.
  • Identify, troubleshoot and resolve mechanical and system‑level issues in a timely manner, often in urgent and high‑priority scenarios.
  • Perform root cause analysis of failures and implement corrective actions.
  • Support environmental, vibration, thermal and functional testing activities.
• Integration & Sustainment
  • Integrate new mechanical systems and components into existing platforms and infrastructure.
  • Support fabrication, assembly, installation and maintenance activities for deployed systems.
  • Coordinate with manufacturing, technicians, engineers and suppliers to ensure successful hardware implementation.
  • Perform routine maintenance, upgrades and configuration improvements on mechanical and electromechanical equipment for communications equipment and antenna systems.
• Customer & Team Interaction
  • Work closely with a small and highly effective team to support various customers in understanding their needs to provide technical support and meet their requirements.
  • Collaborate with multidisciplinary engineering teams to ensure project success.
  • Communicate project status and technical information effectively to peers and leadership.

• Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, Manufacturing/Industrial Engineering, or a related technical field, or equivalent work experience.
• 5–10+ years of proven experience in mechanical design and product development.
• Strong experience with full‑lifecycle engineering (concept development, design, prototyping, testing, integration, manufacturing support, and sustainment).
• Proficiency with Solid Works 3D CAD/CAM software, etc.
• Experience creating technical drawings, specifications, documentation and design analyses.
• Hands‑on experience with fabrication, assembly, testing and troubleshooting complex mechanical systems.
• Strong understanding of materials, machining processes, fasteners, tolerance stack‑ups and manufacturing methods (e.g., additive manufacturing/3D printing, CNC machining, injection molding, etc.).
• Experience working with hand tools, power tools, precision measurement equipment and shop equipment.
• Excellent interpersonal and communication skills, able to interact effectively with customers and peers.
• Demonstrated ability to work effectively in a high‑stress, high‑speed environment.
• Ability to work both independently and collaboratively within a multi‑disciplinary team.
• Demonstrates strong initiative, self‑motivation, and a proactive approach to problem‑solving without requiring constant direction.
• Active DoD Secret clearance with the ability to obtain and maintain a DoD TS/SCI clearance.
• Ability to lift and/or move 50 pounds.

In compliance with applicable pay transparency laws, the expected salary range for this position is $112,000 – $190,000 per year,…