Mechanical Engineer - Sustaining

CACI International Inc.; Los Gatos (CA); On-site; USD 87,000 - 182,000; Full time

Job summary

CACI International Inc. is seeking a hands-on Mechanical Engineer to sustain and bridge design and production for space-based laser communications hardware. You will diagnose issues, perform root cause analysis, and work with manufacturing and suppliers to improve quality, yield, and manufacturability.

The role focuses on design verification, environmental testing, ECO management, and documentation as products transition to full-scale production, with up to 25% travel within the United States.

Qualifications

• Requires B.S./M.S. in Mechanical Engineering.
• Must be a US citizen.
• 5+ years in mechanical design, analysis and testing.
• Experience creating/releases of complex mechanical models, drawings, and assemblies.
• Proficient with SolidWorks and PDM/PLM; GD&T knowledge.
• Proficient with MS Office tools (Word, PowerPoint, Excel).
• Strong written, verbal and visual communication skills.
• Self-starter who owns tasks and drives to completion.
• Willing to travel up to 25% within the U.S.

Responsibilities

• Diagnose and resolve complex issues across optics, mechanics, electronics, and control systems.
• Lead root cause analysis and CAPA for production deviations and non-conformances.
• Collaborate with manufacturing to improve assembly processes and yield.
• Support design verification and environmental testing; closure of verification activities.
• Manage ECOs and present failure analyses with multi-disciplinary teams.

Skills

US Citizenship

Strong communication

Problem solving

Self-starter

Cross-functional

Education

B.S. or M.S. Mechanical Engineering

Tools

SolidWorks

PDM/PLM

GD&T ASME Y14.5

Mechanical drafting standards

Microsoft Office

Job description

Job Title: Mechanical Engineer - Sustaining

Job Category: Engineering

Time Type: Full time

Minimum Clearance Required to Start: None

Employee Type: Regular

Percentage of Travel Required: Up to 25%

Type of Travel: Continental US

CACI is looking for staff to join our Photonics team developing space-based laser communications technology. We are seeking a hands-on Sustaining Engineer to bridge the gap between design and production, supporting our complex optomechanical and electromechanical systems. In this role, you will diagnose issues, drive root cause investigations, and partner with manufacturing and suppliers to continuously improve quality, yield, and manufacturability. You will also execute design verification and environmental testing, and provide engineering support as new products transition into full-scale production. This is an excellent opportunity for an engineer who thrives on solving multidisciplinary problems and wants hands-on ownership of technical issues and process improvements in a design through production environment.

The Opportunity:

Technical Problem-Solving & Root Cause Analysis

• Diagnose and resolve complex issues spanning optics, mechanics, electronics, and control systems, encountered during build, test, and integration.
• Lead root cause analysis (RCA) and corrective action (CAPA) efforts for performance deviations, test failures, and non-conformances identified in production.

Manufacturing & Supplier Collaboration

• Collaborate with manufacturing teams to address yield issues, improve assembly processes, and implement design-for-manufacturing enhancements.
• Work directly with suppliers to address fabrication issues and yield improvements

Design Verification and Acceptance Testing

• Support and execute product acceptance and environmental testing (including vibration, shock, thermal, etc.).
• Support closure of design verification activities.
• Contribute to continuous improvement of design, test, and build processes

Design and Documentation Management

• Manage engineering change orders (ECOs) to update designs, drawings, and documentation.
• Present failure analysis and proposed design changes to multidiscipline design and manufacturing teams.
• Create and edit procedures and test reports.

Qualifications:

Required:

• B.S. or M.S. in Mechanical Engineering.
• Must be a US Citizen.
• 5+ years of industry experience in mechanical design, analysis, and testing.
• Demonstrated experience creating and releasing complex mechanical models, drawings, and assemblies.
• Strong proficiency with SolidWorks and PDM/PLM systems. Knowledge of GD&T (ASME Y14.5) and mechanical drafting standards.
• Experience working with Microsoft Office tools (Word, PowerPoint, Excel).
• Strong written, verbal, and visual communication skills.
• A self-starter with excellent problem-solving skills who takes ownership of assigned tasks and drives them to completion.
• Comfortable working cross-functionally and reaching out across departments to resolve issues
• Ability to work in an environment needing to balance multiple priorities, and move fluidly between big-picture strategy and detailed execution
• Strong attention to detail and a collaborative, can-do attitude
• 25% travel within the U.S. may be required.

Desired:

• Experience with aerospace, defense, or other high-reliability industries.
• Background in optomechanical systems, precision structures, or high-stability mechanical assemblies.
• Experience with gimbal systems or other precision motion control mechanisms, including design, integration, and optimization for applications in optical systems or robotics.
• Familiarity with material behavior in space environments (e.g., CTE matching, thermal gradients, outgassing)
• Knowledge of Design for Manufacturing (DFM) and Design Failure Mode and Effects Analysis (DFMEA) methodologies, with applied experience improving product quality and manufacturability.
• Experience in environmental testing to MIL-STD or equivalent industrial test levels, including shock, vibration, thermal, and EMI/EMC.

What You Can Expect:

A culture of integrity.At CACI, we place character and innovation at the center of everything we do. As a valued team member, you’ll be part of a high-performing group dedicated to our customer’s missions and driven by a higher purpose – to ensure the safety of our nation.

An environment of trust.CACI values the unique contributions that every employee brings to our company and our customers - every day. You’ll have the autonomy to take the time you need through a unique flexible time off benefit and have access to robust learning resources to make your ambitions a reality.

A focus on continuous growth.Together, we will advance our nation's most critical missions, build on our lengthy track record of business success, and find opportunities to break new ground — in your career and in our legacy.

Pay Range:

There are a host of factors that can influence final salary including, but not limited to, geographic location, Federal Government contract labor categories and contract wage rates, relevant prior work experience, specific skills and competencies, education, and certifications. Our employees value the flexibility at CACI that allows them to balance quality work and their personal lives. We offer competitive compensation, benefits and learning and development opportunities. Our broad and competitive mix of benefits options is designed to support and protect employees and their families. At CACI, you will receive comprehensive benefits such as; healthcare, wellness, financial, retirement, family support, continuing education, and time off benefits.

The proposed salary range for this position is:

$86,600 - $181,800

CACI is an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, pregnancy, sexual orientation, age, national origin, disability, status as a protected veteran, or any other protected characteristic.