Head Opto-Mechanical Engineer, Aerospace Systems

Clear Align, LLC; Nashua, Northern (NH, KY); Hybrid; USD 140,000 - 190,000; Full time

Job summary

Clear Align, LLC in Nashua, NH is seeking a Principal Mechanical Engineer – Opto-Mechanical to lead architecture, analysis, and integration of precision electro‑optic assemblies across aerospace and defense programs. You will guide concept development, requirements definition, detailed design, environmental qualification, production, and field support.

You will mentor engineers, drive trade studies and technical reviews, apply GD&T and MIL standards, and collaborate with systems, optical,

Qualifications

• Bachelor’s degree in Mechanical Engineering or higher.
• 7+ years of experience in opto-mechanical design for aerospace or defense systems.
• Advanced proficiency in SolidWorks or equivalent CAD tools and GD&T per ASME Y14.5.
• Proven experience developing Technical Data Packages, specifications, and conceptual designs.
• Experience in systems thinking including trade studies, analysis of alternatives, developing requirements.
• Strong understanding of DFM/DFA, material properties, tolerance analyses, and design‑to‑cost optimization and environmental qualification requirements.
• Experience in electro‑optic design or manufacturing environments.

Responsibilities

• Lead opto-mechanical design and development across multiple aerospace and defense programs from concept through production and field deployment.
• Develop precision mechanical architectures for electro-optical systems operating in space, airborne, and ground-based environments.
• Perform and lead engineering analyses to validate designs for structural integrity, stiffness, strength, vibration, shock, thermal performance, environmental durability, manufacturability, reliability, schedule, and cost.
• Lead technical trade studies involving structural configuration, materials, mechanisms, thermal management, tolerancing, manufacturability, and system-level performance.
• Develop technical requirements, specifications, concepts, preliminary and detailed designs, engineering analyses, test procedures, assembly procedures, and technical reports.
• Create, review, and approve technical data packages, including fabrication, assembly, interface, source-control, and configuration-controlled drawings, in accordance with ASME Y14.5 and applicable internal and customer standards.
• Apply advanced GD&T and tolerance analysis techniques to ensure optical alignment, mechanical interfaces, and system performance requirements are achieved.
• Specify, select, and integrate electromechanical actuators, precision mechanisms, bearings, flexures, and positioning components used for optical alignment and positioning.
• Conduct or oversee Finite Element Analysis (FEA) and other analytical methods to evaluate structural and mechanical performance.
• Support thermal analysis and thermal-mechanical design of electro-optical assemblies, including interfaces between optical, mechanical, and electronic components.
• Design for and evaluate performance in demanding environments, including vibration, shock, thermal cycling, temperature extremes, contamination, and other applicable aerospace environmental conditions.
• Apply knowledge of MIL-SPECs, MIL-STDs, aerospace standards, component qualification requirements, and component failure modes to product design and development.
• Support engineering development and qualification testing, including test planning, instrumentation, test readiness, data review, failure investigation, and corrective actions.
• Lead technical design reviews, including SRR, PDR, CDR, TRR, and other program milestone reviews, as applicable.
• Author and present technical material during internal, customer, and cross-functional design reviews.
• Proactively identify and mitigate technical, schedule, cost, manufacturing, and supply-chain risks throughout the product lifecycle.
• Work as a technical leader within an Integrated Product Team (IPT), coordinating across mechanical, optical, electrical, systems, manufacturing, quality, test, and program management functions.
• Provide technical mentorship and guidance to mechanical engineers, designers, and technicians, helping establish sound engineering practices and developing the next generation of technical talent.
• Support transition from engineering development to production through design-for-manufacturability, producibility, inspection, assembly, and configuration-management activities.
• Contribute technical content to cost, schedule, technical, and management volumes for proposals, bids, and new business opportunities.
• Support customer engagements and provide technical input to requirements development, solution definition

Skills

Opto-mechanical design

SolidWorks

GD&T ASME Y14.5

Technical Data Packages

Systems thinking

DFM/DFA

Electro-optic design

Education

Bachelor’s degree in Mechanical Engineering

Tools

PDM/PLM/ERP systems

Job description

Clear Align, LLC in Nashua, NH is seeking a Principal Mechanical Engineer – Opto-Mechanical to lead architecture, analysis, and integration of precision electro‑optic assemblies across aerospace and defense programs. You will guide concept development, requirements definition, detailed design, environmental qualification, production, and field support.

You will mentor engineers, drive trade studies and technical reviews, apply GD&T and MIL standards, and collaborate with systems, optical,