Mechanical Engineer

General Atomics; San Diego (CA); On-site; USD 69,000 - 116,000; Full time

Job summary

General Atomics Electromagnetic Systems (GA-EMS) in San Diego, CA seeks a Mechanical Engineer II to design, analyze, integrate, and test mechanical and electromechanical systems across defense, space, and energy applications. You will work from concept through production, contributing to structures, thermal management, and mechanisms, with collaboration across cross‑functional teams.

The role requires a Bachelor's in Mechanical Engineering and 2+ years of progressive experience; familiarity with

Qualifications

• Typically requires a Bachelor's degree in Mechanical Engineering or a related engineering discipline and 2 or more years of progressive mechanical engineering experience.
• Demonstrated proficiency with 3D CAD software (SolidWorks, NX, or Creo) and PDM/PLM tools.
• Working knowledge of GD&T per ASME Y14.5 and engineering drawing practices per ASME Y14.100.
• Experience with structural and/or thermal analysis, including hand calculations and FEA.
• Understanding of common manufacturing processes and their impact on design.
• Ability to work independently on moderately complex tasks and collaboratively within integrated product teams.
• Ability to obtain and maintain a DoD security clearance is required; an active Secret clearance is highly desirable.

Responsibilities

• Design mechanical components, assemblies, and subsystems using 3D CAD tools.
• Produce and check engineering drawings compliant with ASME Y14.5 and ASME Y14.100.
• Perform tolerance stack‑up analyses to ensure fit, form, and function.
• Support design for manufacturability and assembly (DFM/DFA).
• Perform classical hand calculations and FEA for structural/thermal loads.
• Conduct thermal analyses for liquid‑cooled and conduction‑cooled hardware.
• Document analyses and present results at design reviews.
• Support AI&T, test plans, and fielding activities.

Skills

GD&T ASME Y14.5

Hand calculations

FEA

Thermal/structural analysis

Independent work

Education

Bachelor's degree in Mechanical Engineering or related

Tools

SolidWorks

NX

Creo

PDM/PLM tools

Job description

Job Summary

General Atomics Electromagnetic Systems (GA-EMS) designs and manufactures first-of-a-kind electromagnetic and electric power generation systems for defense, space, and energy applications. Our portfolio includes Aircraft Launch and Recovery Equipment (ALRE) such as the Electromagnetic Aircraft Launch System (EMALS) and Advanced Arresting Gear (AAG), satellite buses and electro-optical payloads, high energy laser (HEL) weapon systems, and advanced nuclear reactor technologies. We have an exciting opportunity for a Mechanical Engineer II to join our multidisciplinary engineering team. Under limited supervision, this position is responsible for the design, analysis, integration, and test of mechanical and electromechanical systems across one or more of the following product areas:

• ALRE – electromagnetic launch and recovery hardware, energy storage subsystems, power conversion enclosures, and shipboard mechanical integration
• Space Systems – satellite bus structures, mechanisms, optical payload integration, and spacecraft thermal management
• High Energy Lasers – thermal management systems for laser weapon systems, including liquid cooling loops, cold plates, heat exchangers, and thermal energy storage
• Nuclear Technologies – reactor structural components, pressure-retaining hardware, and support structures for advanced reactor concepts

The successful candidate will work in a fast-paced, hands‑on environment, contributing to hardware from concept through design, analysis, prototyping, qualification, production, and fielding.

DUTIES AND RESPONSIBILITIES

Design & Development

• Design mechanical components, assemblies, and subsystems (structures, enclosures, mechanisms, fluid/thermal hardware) using 3D CAD tools (e.g., SolidWorks, NX, Creo).
• Produce and check engineering drawings compliant with ASME Y14.5 (GD&T) and ASME Y14.100 drawing practices, including parts lists, notes, and configuration documentation.
• Perform tolerance stack‑up analyses to ensure fit, form, and function across assemblies.
• Select materials, finishes, fasteners, and thermal interface materials appropriate for the operating environment (shipboard, space/vacuum, high‑power laser, or nuclear).
• Support design for manufacturability and assembly (DFM/DFA), working closely with machine shops, fabrication vendors, and internal manufacturing teams.

Analysis

• Perform classical hand calculations and finite element analysis (FEA) for structural, thermal, vibration, and shock loading conditions (e.g., ANSYS, Femap/Nastran).
• Conduct thermal analyses of liquid‑cooled and conduction‑cooled hardware; size pumps, cold plates, heat exchangers, and coolant loops for high‑heat‑flux applications.
• Support structural assessments to relevant codes and standards (e.g., MIL‑STD‑810, MIL‑S‑901D shock, MIL‑STD‑167 vibration, GEVS/SMC‑S‑016 for space hardware, ASME B&PV Code Section III/VIII for nuclear and pressure hardware, as applicable).
• Document analyses in formal reports and present results at design reviews.

Integration & Test

• Support assembly, integration, and test (AI&T) of prototype and production hardware, including satellite payload integration and laser system thermal subsystem checkout.
• Develop test plans, procedures, and fixtures; conduct engineering development tests, qualification tests, and acceptance tests.
• Troubleshoot hardware issues on the production floor and in the field; perform root cause and corrective action (RCCA) investigations.
• Support shipboard, range, or customer‑site installation and test activities as required.

Program & Cross‑Functional Support

• Participate in design reviews (SRR, PDR, CDR, TRR) and prepare associated technical data packages.
• Interface with electrical, systems, software, quality, supply chain, and manufacturing engineering to ensure integrated product solutions.
• Support proposal efforts with design concepts, trade studies, mass/thermal budgets, and basis‑of‑estimate inputs.
• Generate and maintain engineering documentation including specifications, interface control documents (ICDs), engineering change orders (ECOs), and nonconformance dispositions.
• Ensure compliance with applicable quality standards (AS9100), ESD control programs (ANSI/ESD S20.20), and safety requirements.
• Maintain the strict confidentiality of sensitive information.

We recognize and appreciate the value and contributions of individuals with diverse backgrounds and experiences and welcome all qualified individuals to apply.

Job Qualifications

• Typically requires a Bachelor's degree in Mechanical Engineering or a related engineering discipline from an accredited institution and 2 or more years of progressive mechanical engineering experience. May substitute a Master's degree with less experience, or equivalent additional experience in lieu of a degree.
• Demonstrated proficiency with 3D CAD software (SolidWorks, NX, or Creo) and PDM/PLM tools.
• Working knowledge of GD&T per ASME Y14.5 and engineering drawing practices per ASME Y14.100.
• Experience with structural and/or thermal analysis, including hand calculations and FEA.
• Understanding of common manufacturing processes (machining, sheet metal, welding, castings, composites) and their impact on design.
• Ability to work independently on moderately complex tasks and collaboratively within integrated product teams.
• Strong written and verbal communication skills, including the ability to document work and present to internal and customer audiences.
• Ability to obtain and maintain a DoD security clearance is required; an active Secret clearance is highly desirable.

Desired Qualifications

• Experience in one or more of the following domains:
• Shipboard or military hardware design (shock, vibration, and EMI‑driven design; MIL‑S‑901D, MIL‑STD‑167)
• Spacecraft structures, mechanisms, or optical payload integration (cleanliness, contamination control, alignment, launch loads)
• Liquid thermal management for high‑power electronics or directed energy systems (cold plates, TIMs, gap fillers, coolant chemistry)
• Nuclear or pressure vessel hardware design to ASME B&PV Code
• Experience with thermal/fluid analysis tools (ANSYS Icepak/Fluent, Thermal Desktop, FloEFD) or structural tools (ANSYS Mechanical, Femap/Nastran).
• Familiarity with MIL‑STD‑810 environmental testing and qualification programs.
• Hands‑on experience supporting hardware build, integration, and test in a lab or production environment.
• Familiarity with AS9100 quality systems, configuration management, and ESD‑safe practices (ANSI/ESD S20.20).
• Experience with tolerance analysis tools and model‑based definition (MBD).
• EIT/FE certification or progress toward PE licensure.

Physical & Environmental Requirements

• Ability to work in office, laboratory, production floor, and occasional field/shipboard environments.
• May require lifting up to 25 lbs, working around energized equipment and pressurized fluid systems, and wearing appropriate PPE.
• Vision (with or without correction) adequate for detailed design and inspection work.

Job Type: Full-Time Salary

Salary range: 68,770 - 116,193