Mechanical Design Engineer II/III

IPG Defense; Huntsville (AL); Hybrid; USD 90,000 - 120,000; Full time

Benefits offered by this job

Medical, dental, and vision insurance

401(k) with company matching

ESPP

Tuition Reimbursement

Paid holidays

Parental bonding leave

Job summary

IPG Defense, based in Huntsville, AL, seeks a Mechanical Design Engineer to create ruggedized, opto-mechanical hardware for directed-energy systems. You will design in SolidWorks from concept to production, collaborate with machine shops, and manage data in PDM.

Level II/III depends on experience and qualifications. Responsibilities include 3D CAD, drawings, tolerancing, and BOM management, plus prototyping with additive manufacturing and support through production.

Qualifications

• Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, or a closely related engineering discipline.
• 3–7 years of mechanical design experience with complex mechanical systems, ruggedized equipment, or similar demanding applications.
• Proficiency in SolidWorks, including detailed drafting, engineering drawings, and GD&T.
• Experience with drawing releases, drawing templates, and formal documentation practices.
• Experience with SolidWorks PDM for design data and revision management.
• Experience with opto-mechanical design and/or enclosure design for environmental requirements.
• Experience working with machine shops on design-for-manufacturability.
• Experience with additive manufacturing and 3D printing for prototypes or production parts.
• Strong written and verbal communication skills; ability to collaborate across engineering, manufacturing, quality, and suppliers.

Responsibilities

• Create detailed 3D CAD models, assemblies, and production drawings in SolidWorks, applying GD&T.
• Prepare and maintain engineering drawings, drawing templates, and release packages; execute drawing releases and revisions through formal configuration control.
• Manage design data in SolidWorks PDM, including file structure, revision control, and BOM accuracy.
• Design opto-mechanical mounts, beam-delivery structures, and precision alignment features for high-energy laser systems.
• Design sealed, ruggedized enclosures and electronics packaging for harsh operating environments (thermal, shock, vibration, ingress).
• Perform tolerance stack-up analyses to verify fit, alignment, and performance.
• Work directly with machine shops on design-for-manufacturability, quoting, and fabrication issues; incorporate shop feedback into designs.
• Use additive manufacturing and in-house 3D printers for rapid prototyping, fixtures, and tooling.
• Support prototype builds, system integration, and acceptance testing; troubleshoot fabrication and assembly issues and implement corrective actions.
• Participate in design reviews, trade studies, and technical interchange meetings.

Skills

SolidWorks

GD&T

Drafting

PDM

Opto-mechanical design

Enclosure design

DFM

Additive manufacturing

Manufacturing liaison

Communication

Education

Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, or a closely related engineering discipline

Tools

SolidWorks

SolidWorks Simulation

ANSYS

Job description

POSITION INFORMATION

• Department / Function Engineering – IPG Defense
• Reports To Chief Engineer
• Work Location Huntsville, AL
• Employment Type Full-time (Exempt)
• Travel Less than 10%.
• Security / Clearance Not required; active DoD security clearance preferred.

ABOUT IPG DEFENSE

IPG Defense, a stand-alone business of IPG Photonics, was incorporated in 2026 to provide direct support for defense products. Headquartered in Huntsville, AL, IPG Defense is bringing commercial scale to laser defense systems, leveraging IPG Photonics’ 36 years of experience in fiber laser technology. Our mission: develop and deliver the most advanced, next-generation laser defense solutions for military and civilian use - systems that accurately and reliably detect, track, target, and neutralize threats.

IPG Photonics is the world’s leading developer and manufacturer of high-performance fiber lasers and amplifiers for diverse applications in numerous markets. Founded in 1990, IPG pioneered the development and commercialization of optical fiber-based lasers — a critical technology in our high-energy laser (HEL) systems, including the CROSSBOW program.

Your skills and experience will play a key role in shaping our growing organization, building our capabilities, and delivering on our mission. Join us and build a career that will shape the future of laser defense.

POSITION SUMMARY

IPG Defense is seeking a Mechanical Design Engineer to design and document ruggedized mechanical and opto-mechanical hardware for advanced directed-energy systems and military platforms. Working in SolidWorks from concept through production release, this mid-to-senior-level role owns detailed design, drafting, and data management for parts and assemblies that must perform in demanding field environments — and works hand-in-hand with machine shops, additive manufacturing, and integration teams to get hardware built right. Level (II or III) will be determined based on the candidate’s experience and qualifications.

KEY RESPONSIBILITIES

Design & Drafting

• Create detailed 3D CAD models, assemblies, and production drawings in SolidWorks, applying GD&T and dimensional tolerancing best practices.
• Prepare and maintain engineering drawings, drawing templates, and release packages; execute drawing releases and revisions through formal configuration control.
• Manage design data in SolidWorks PDM, including file structure, revision control, and BOM accuracy.

Opto-Mechanical & Enclosure Design

• Design opto-mechanical mounts, beam-delivery structures, and precision alignment features for high-energy laser systems.
• Design sealed, ruggedized enclosures and electronics packaging for harsh operating environments (thermal, shock, vibration, ingress).
• Perform tolerance stack-up analyses to verify fit, alignment, and performance.

Manufacturing & Prototyping

• Work directly with machine shops on design-for-manufacturability, quoting, and fabrication issues; incorporate shop feedback into designs.
• Use additive manufacturing and in-house 3D printers for rapid prototyping, fixtures, and tooling.
• Support prototype builds, system integration, and acceptance testing; troubleshoot fabrication and assembly issues and implement corrective actions.

Lifecycle Support

• Participate in design reviews, trade studies, and technical interchange meetings.
• Support engineering change orders and design modifications through production and sustainment.

MINIMUM QUALIFICATIONS

• Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, or a closely related engineering discipline.
• 3–7 years of mechanical design experience with complex mechanical systems, ruggedized equipment, or similar demanding applications.
• Proficiency in SolidWorks, including detailed drafting, engineering drawings, and GD&T.
• Experience with drawing releases, drawing templates, and formal documentation practices.
• Experience with SolidWorks PDM for design data and revision management.
• Experience with opto-mechanical design and/or enclosure design for environmental requirements.
• Experience working with machine shops on design-for-manufacturability.
• Experience with additive manufacturing and 3D printing for prototypes or production parts.
• Strong written and verbal communication skills; ability to collaborate across engineering, manufacturing, quality, and suppliers.

PREFERRED QUALIFICATIONS

• Active DoD security clearance.
• Experience with defense, aerospace, or other highly regulated engineering environments.
• Experience with directed-energy, laser, or electro-optical systems.
• FEA / thermal-structural analysis experience (SolidWorks Simulation, ANSYS, or similar).
• Familiarity with MIL-STD-810 environmental qualification and testing of hardware for harsh conditions.
• Experience designing test fixtures and tooling.
• Experience with vehicle-mounted systems or power distribution equipment.
• Familiarity with formal configuration management and engineering change processes.

WORK ENVIRONMENT & PHYSICAL REQUIREMENTS

• Office, laboratory, and manufacturing floor settings.
• Occasional lifting up to 25 lbs and use of PPE including laser-safety eyewear.

WHY JOIN IPG DEFENSE

• Work at the forefront of directed-energy and photonics innovation on systems that matter to national security.
• Vertically integrated technology: we design and build our own lasers, giving engineers end-to-end ownership from component to fielded system.
• Small, expert, fast-moving team in Huntsville, AL - one of the nation’s fastest-growing aerospace and defense hubs.
• Career growth through hands-on work across the full product lifecycle: concept, prototype, integration, field test, and production.
• Competitive salary and a comprehensive benefits package - see Compensation & Benefits below.

COMPENSATION & BENEFITS

Other Compensation:

Employees hired at the senior level are eligible for additional rewards which could include:

• Annual Discretionary Bonus

Benefits Provided:

All Regular US employees receive:

• Paid vacation time accrued based on years of service
• Paid sick time
• 12 (twelve) Paid Holidays Each Calendar Year

Additional Benefits Offered:

• Medical, dental, and vision insurance plans with options for HSA/FSA
• Dependent Care FSA
• Paid Basic Life and AD&D Insurance
• Short-term and Long-term Disability insurance
• 401(k) plan with Company matching
• Employee Stock Purchase Plan (ESPP)
• Tuition Reimbursement Program
• Employee Assistance Program (EAP)
• Adoption Assistance
• Pet Insurance
• Parental Bonding Leave
• Bright Horizons Backup Care
• Bright Horizons College Coach

EQUAL EMPLOYMENT OPPORTUNITY

IPG Defense is an Equal Opportunity Employer. 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.