Cleared Senior/Principal R&D Mechanical Engineer - Process Owner, Onsite

Sandia National Laboratories; New Mexico; On-site; USD 117,500 - 235,700; Full time

Job summary

Sandia National Laboratories seeks a cleared Senior/Principal R&D Mechanical Engineer to own and lead manufacturing processes for energetic components at onsite facilities. You will develop, improve, and monitor processes including cleaning, welding, sealing, powder pressing, and metrology, while ensuring design requirements, schedule, and budget alignment.

The role requires a DOE Q clearance to start and offers ownership of process development, equipment qualification, and continuous

Qualifications

• Bachelor’s degree in a relevant discipline with five years of directly relevant experience.
• Active DOE Q clearance or equivalent to start.
• Graduate degree in Mechanical Engineering or related field (Desire).
• Experience with mechanical engineering and product realization in the NNSA complex.
• Strong verbal and written communication skills and ability to work in multidisciplinary teams.
• Experience in high‑quality manufacturing environments applying rigorous processes.
• Familiarity with manufacturing methods such as resistance welding, laser welding, leak checking, soldering, visual inspection, powder pressing, vacuum systems, and metrology.
• Background in explosive technologies and engineering applications.

Responsibilities

• Plan, conceive, conduct, and manage process development for energetic components in a manufacturing environment.
• Direct systematic studies to characterize processes and determine ideal equipment, tools, and parameters.
• Manage and maintain manufacturing equipment ensuring continuous, predictable operation.
• Analyze manufacturing performance using yield, variance, and takt time KPIs.
• Provide Design for Manufacturability input to engineers from Design and Production Agencies.
• Lead or participate in problem‑solving to address manufacturing anomalies and improve processes.
• Develop and maintain work instructions and operating procedures.
• Lead or participate in new process and equipment development and qualification.

Education

Bachelor’s degree in a relevant discipline

Tools

GD&T

Job description

Cleared Senior/Principal R&D Mechanical Engineer - Process Owner, Onsite

Sandia National Laboratories is the nation’s premier science and engineering lab for national security and technology innovation, with teams of specialists focused on cutting‑edge work in a broad array of areas.

What Your Job Will Be Like

We are seeking an experienced R&D Mechanical Engineer to lead and own manufacturing processes at Sandia’s explosive components facilities. Your primary role will consist of working in a flexible team environment to develop, improve, and monitor equipment and methods used for the manufacturing of explosive components with an initial emphasis on assembly operations. You will coordinate with other personnel to apply engineering concepts and best practices to the design, development, analysis, and testing of processes and equipment that meet design requirements on schedule and budget in support of key deliverables. Processes include, but are not limited to cleaning, laser welding, resistance welding, leak testing, powder pressing, encapsulation, soldering, glass‑to‑metal sealing, thin film deposition, mechanical/electrical measurements, and visual inspections. The role also includes ownership of the documentation necessary to manufacture components such as work instructions and operating procedures, as well as the analysis and disposition of non‑conforming product and identifying and implementing opportunities for continuous improvement of yields, methods, and equipment.

On Any Given Day, You May Be Called on to

• Plan, conceive, conduct, and manage process development for energetic components in a manufacturing environment
• Direct systematic studies to characterize processes with the intent of determining the ideal process equipment, tools, and parameters that will meet design requirements with high yield and high quality
• Manage and maintain manufacturing equipment and operational technology ensuring continuous, predictable operation
• Analyze the performance of manufacturing processes using key performance indicators such as yield, variance, and tact time
• Use manufacturing process results and data to provide objective Design for Manufacturability advice to engineers from both the Design and Production Agencies
• Create new understanding and capabilities by using the scientific method: hypothesis, test, and evaluation techniques; critical review; or similar engineering research and development methods
• Use engineering principles to research, design, or develop tooling, instruments, machines, experiments, processes, systems, theories, and technologies
• Lead and support formal problem‑solving efforts as needed to address manufacturing anomalies and to maintain high‑rigor, high‑quality processes
• Develop and maintain work instructions and operating procedures
• Lead or participate in new process and equipment development and qualification
• Assist with the operational startup of a new facility

Due to the nature of the work, the selected applicant must be able to work onsite.

Salary Range

$117,500 - $235,700

*Salary range is estimated, and actual salary will be determined after consideration of the selected candidate’s experience and qualifications, and application of any approved geographic salary differential.

Qualifications We Require

A bachelor’s degree in a relevant discipline and five (5) years of directly relevant experience, or an equivalent combination of directly relevant education and engineering or scientific experience that demonstrates the knowledge, skills, and ability to perform independent research and development.

An active DOE Q Clearance, or equivalent, is required to start.

Qualifications We Desire

• Graduate degree in Mechanical Engineering or a highly related field where an independent research project was a graduation requirement (e.g., independent project, thesis, or dissertation)
• Experience with mechanical engineering and product realization in the NNSA complex
• Strong verbal and written communication skills, ability to work effectively in multidisciplinary teams
• Experience in a high‑quality manufacturing environment applying rigorous processes
• Experience in interfacing with and participating in Product Realization Team
• Installation, qualification, and maintenance of manufacturing process equipment experience
• Familiarity with manufacturing methods such as resistance welding, laser welding, leak checking, soldering, visual inspection, powder pressing, vacuum systems, and metrology
• Familiarity with machining metals, glass, and ceramics
• Metallographic sample preparation processes such as mounting, sectioning, grinding, and polishing
• Developing, maintaining, and improving manufacturing processes including developing fixtures and tooling with lean manufacturing principals and statistical process control
• Experience with hazardous operations
• Demonstrated ability to analyze data and apply the analysis to decision making
• Familiarity with engineering drawings, including Geometric Dimensioning and Tolerancing (GD&T)
• Background in, or experience with, explosive technologies and engineering applications
• Demonstrated ability to successfully manage multiple tasks and projects

About Our Team

The Explosive Component Operations Science and Technology department (7457) produces energetic components that support deliverables for Sandia’s nuclear deterrence mission. We also provide mission‑enabling support to all of 7450, while innovating energetic component processes and production capabilities for the organization. We are responsible for production planning, product pre‑acceptance, and component manufacturing. We oversee the construction and operations of the Energetics Manufacturing Science and Technology (EMSAT) facility.

Security Clearance

Position requires a Department of Energy (DOE) Q security clearance to start, or equivalent active security clearance with another U.S. government agency (e.g., DOD). Sandia is required by DOE directive to conduct a pre‑employment drug test and background review that includes checks of personal references, credit, law enforcement records, and employment/education verifications. Applicants for employment need to be able to maintain a DOE Q‑level security clearance, which requires U.S. citizenship. If you hold more than one citizenship (i.e., of the U.S. and another country), your ability to obtain a security clearance may be impacted.

Applicants offered employment with Sandia are subject to a federal background investigation to meet the requirements for access to classified information or matter if the duties of the position require a DOE security clearance. Substance abuse or illegal drug use, falsification of information, criminal activity, serious misconduct or other indicators of untrustworthiness can cause a clearance to be denied or terminated by DOE, resulting in the inability to perform the duties assigned and subsequent termination of employment.

EEO

All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, age, disability, or veteran status and any other protected class under state or federal law.

NNSA Requirements for MedPEDs

If you have a Medical Portable Electronic Device (MedPED), such as a pacemaker, defibrillator, drug‑releasing pump, hearing aids, or diagnostic equipment and other equipment for measuring, monitoring, and recording body functions such as heartbeat and brain waves, if employed by Sandia National Laboratories you may be required to comply with NNSA security requirements for MedPEDs.

If you have a MedPED and you are selected for an on‑site interview at Sandia National Laboratories, there may be additional steps necessary to ensure compliance with NNSA security requirements prior to the interview date.