Senior Mechanical Engineer

Join CHAOS, a leading company in the aerospace and defense industry, as a Senior Mechanical Engineer. In this role, you will be responsible for the hands-on design, development, packaging, integration, and qualification of ruggedized sensor systems, avionics, electronic hardware, and related mission-critical systems. You will work across the entire product lifecycle, from concept development to production and sustainment. The ideal candidate will have a strong background in mechanical design and integration of electronic hardware, as well as experience with complex assemblies and integrated systems.

• Support the design, development, packaging, integration, and qualification of ruggedized sensor systems and avionics.
• Develop and maintain 3D CAD models, complex assemblies, detailed drawings, installation documentation, and interface control documents.
• Collaborate with mechanical, electrical, RF, power, manufacturing, systems engineering, customers, suppliers, and platform providers to resolve integration challenges.

• The ideal candidate brings strong mechanical design and CAD expertise, experience with complex assemblies and integrated systems, and demonstrated prototyping, analysis, and problem-solving skills
• 4+ years of relevant experience in mechanical design and integration of electronic hardware for aerospace, defense, or similar applications
• Understanding of mechanical interfaces, tolerancing, alignment, installation practices, GD&T, tolerance analysis, and configuration-controlled documentation
• Familiarity with structural analysis methods, including hand calculations and FEA
• Strong problem-solving skills, attention to detail, and ability to work effectively in fast-paced, multi-disciplinary development environments
• Familiarity with ruggedized hardware and applicable environmental requirements
• Strong proficiency with mechanical CAD tools, such as SolidWorks or equivalent, including complex parts and assemblies
• Ability to obtain and maintain a U.S. security clearance
• Experience designing or integrating mechanical hardware for RF, avionics, power electronics, embedded computing, or similar products
• Experience supporting prototype builds, integration, testing, or qualification activities
• Bachelor’s degree in Mechanical Engineering or a related discipline
• Experience producing and reviewing production-ready mechanical drawings and documentation
• Master’s degree in Mechanical Engineering or a related field
• Experience supporting environmental qualification testing and analysis, including thermal cycling, vibration, and shock
• Experience with commercial FEA or multiphysics simulation tools, such as NASTRAN, ABAQUS, ANSYS, COMSOL, or similar tools
• Familiarity with military and aerospace standards, including MIL-STD-810
• Familiarity with military and aerospace connectors, such as MIL-DTL-38999, ARINC, and Micro-D
• Experience with mechanisms, actuation systems, structures, thermal management, packaging, cable routing, connector layouts, or electromechanical integration
• Experience with additive manufacturing, CNC machining, fabrication, assembly, and prototype development
• Hands-on experience working with machine shop and prototype lab equipment