Mechanical Design Engineer

TSC; Washington (District of Columbia); On-site; USD 112,000 - 190,000; Full time

Job summary

TSC in Washington, DC area seeks a Mechanical Design Engineer to own full lifecycle development of advanced mechanical systems for communications hardware. You will design, prototype, test, and integrate robust assemblies, collaborating with multidisciplinary teams onsite.

The role requires 5–10+ years of hands-on experience, SolidWorks proficiency, DoD clearance eligibility, and the ability to lift 50 pounds.

Qualifications

• 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.
• Proficiency with SolidWorks 3D CAD/CAM software.
• Experience creating technical drawings, specifications, documentation and design analyses.
• Hands‑on 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).
• 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.
• Active DoD Secret clearance with the ability to obtain and maintain a DoD TS/SCI clearance.
• Ability to lift and/or move 50 pounds.

Responsibilities

• Mechanical System Design & Development: Design and develop robust mechanical systems and components; translate requirements into design specs.
• Prototyping, Testing & Troubleshooting: Develop test plans; build, evaluate and troubleshoot prototypes; perform root cause analyses.
• Integration & Sustainment: Integrate systems into platforms; support fabrication, installation and maintenance.
• Customer & Team Interaction: Collaborate with customers and multidisciplinary teams; communicate project status clearly.

Skills

Mechanical design experience

Full lifecycle engineering

Clear communication

Team collaboration

Problem solving

DoD clearance eligibility

SolidWorks proficiency

Fabrication and testing

Root cause analysis

Independent & proactive work

Education

Bachelor's in Mechanical/Aerospace/Manufacturing/Industrial Engineering

Tools

SolidWorks

Job description

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.

Responsibilities

• 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.

Required Qualifications

• 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 SolidWorks 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.

Job Details

In compliance with applicable pay transparency laws, the expected salary range for this position is $112,000 – $190,000 per year, depending on experience and location. This role is also eligible for an annual performance bonus and may include equity or incentive compensation as part of the total rewards package.

U.S. Citizenship Required for this Position: Yes

Eligibility to Obtain a DoD Security Clearance Required for this Position: Yes, will be required to obtain and maintain a security clearance.

Travel: Some (local)

Relocation Assistance Available: No

Position Contingent Upon Award of Contract: No

Benefits

TSC offers a stable work environment, a competitive salary, and a comprehensive benefit package; including ESOP participation, 401k Plan, Flexible Work Schedules, Tuition Reimbursement, Co‑Sponsored Health Plan, Paid Leave and much more.

Employment Requirements

Employment at TSC is contingent upon the successful completion of a comprehensive background check, security investigation, and drug screening. Contractors shall abide by the requirements of 41 CFR 60–1.4(a), 60–300.5(a), and 60–741.5(a), which prohibit discrimination and require affirmative action.

EEO Statement

All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, disability, or status as a protected veteran.