Mechanical Research and Development Engineer

The Applied Research Laboratory at Penn State University; Warminster Township (Bucks County); Hybrid; USD 116,496 - 220,884; Full time

Job summary

The Applied Research Laboratory at Penn State University in Warminster, PA seeks a Mechanical Research and Development Engineer to design, analyze, and test structures and multi-material assemblies, including fiber-reinforced polymer composites, and to advance innovative design methods.

You will create detailed CAD models, perform FEA, script in MATLAB/Python, conduct laboratory experiments, and collaborate with senior engineers on integrated system architectures while supporting DoD-related

Qualifications

• Bachelor's Degree in Engineering or Science required.
• 5+ years relevant experience for ARL-Advanced Professional path; 2+ years for Intermediate path.

Responsibilities

• Perform analytical and computational modeling to evaluate system and structural behavior.
• Develop detailed mechanical designs and assemblies using CAD software.
• Conduct laboratory testing to validate analytical models.
• Support system and subsystem integration and interface analysis.
• Mentor junior engineers and contribute to technical leadership.

Skills

FEA modelling

CAD design

MATLAB/Python

mult-material assemblies

team collaboration

Education

Bachelor's Degree in Engineering or Science

Tools

SolidWorks

Creo

NX

Abaqus

Job description

Position specifics

We are searching for a high motivated Mechanical Research and Development Engineer to join our Advanced Design & Analysis Department at the Applied Research Laboratory (ARL) at Penn State. This role will involve designing, analyzing, and testing structures and systems, including multi-material assemblies, including fiber-reinforced polymer composite structures and other advanced materials.

ARL is an authorised DoD SkillBridge partner and welcomes all transitioning military members to apply.

FOR FURTHER INFORMATION on ARL, visit our website at www.arl.psu.edu.

Approval of remote and hybrid work is not guaranteed regardless of work location. For additional information on remote work at Penn State, see Notice to Out of State Applicants.

You will

• Perform analytical and computational modeling to evaluate system and structural behavior, component interactions, and overall design performance
• Develop detailed mechanical designs and assemblies using mechanical CAD software
• Conduct laboratory testing to validate analytical models
• Flexibly to adapt across a variety of technical tasks, including CAD modeling, scripting in MATLAB/Python, analytical modeling, and supporting experimental testing
• Collaborate closely with senior engineers, receiving mentorship in modeling, design methodologies, and interdisciplinary engineering practices
• Support system and subsystem integration efforts by analyzing interfaces, ensuring compatibility, and contributing to the development of fully integrated system architectures
• Perform detailed finite element analysis of multi-material systems as part of broader design and integration activities, supporting structural evaluation, system modelling, and engineering decision-making

Additional responsibilities for higher-level position includes:

• Support research conducted within Unclassified, Controlled Unclassified Information (CUI), and Classified environments while safeguarding sensitive technical information and government-furnished data
• Participate in technology transition activities, including system integration, operational demonstrations, customer evaluations, manufacturing support, and field implementation
• Identify technical risks and develop mitigation strategies to improve program execution, system performance, reliability, maintainability, and mission effectiveness
• Initiate and contribute to business development activities through technical concept development, customer engagement, proposal preparation, Independent Research and Development (IRAD) initiatives, and strategic technology planning
• Mentor and provide technical leadership to junior engineers, engineering technologists, engineering support personnel, interns, and students
• Maintain technical expertise through continued professional development, participation in technical working groups, awareness of emerging technologies, and engagement with the defense research community

Required skills/experience areas include:

• Finite element analysis (FEA) modelling and structural analysis of multi-material systems
• CAD software, such as SolidWorks, Creo, or NX
• Programming skills (MATLAB/Python)
• Ability to quickly adapt to diverse engineering tasks and changing project priorities
• Demonstrated collaboration within a multidisciplinary team

Preferred skills/experience areas include:

• Abaqus or similar advanced FEA software
• Past success with multi-material assemblies and integrated system architectures
• Mechanical testing methods and laboratory experiments
• Modelling, subsystem integration, or interface analysis

Your working location will be a hybrid of on-site/work from home, on-site location is Warminster, PA

Minimum education, work experience & required certifications

If filled as R&D Engineer - Mechanical (ARL) - Advanced Professional, this position requires: Bachelor's Degree - Engineering or Science 5+ years of relevant experience Required Certifications: None If filled as R&D Engineer - Mechanical (ARL) - Intermediate Professional, this position requires: Bachelor's Degree - Engineering or Science 2+ years of relevant experience Required Certifications: None

ARL's purpose is to research and develop innovative solutions to challenging scientific, engineering, and technology problems in support of the Navy, the Intel Community (IC), and other federal government customers.

Background checks/clearances

Employment with the University will require successful completion of background check(s) in accordance with University policies.

Notice regarding employment at the Applied Research Laboratory (ARL): Employees must be eligible to obtain a government security clearance, participate in the ARL drug testing program, and comply with electronic and physical monitoring requirements applicable to federal contractors. ARL operates in a secure information environment involving Unclassified, Controlled Unclassified Information (CUI), and Classified information. Personal electronic devices brought onsite must be registered and may be restricted from certain areas. You must be a U.S. citizen to apply.

Salary & benefits

The salary range for this position, including all possible grades, is $116,496.00 - $220,884.00. This salary range includes an adjustment based on required geographic work location.

Salary Structure - Information on Penn State's salary structure

Penn State provides a competitive benefits package for full-time employees designed to support both personal and professional well-being.

• comprehensive medical, dental, and vision coverage
• robust retirement plans
• substantial paid time off which includes holidays, vacation and sick time
• generous 75% tuition discount, available to employees as well as eligible spouses and children

Campus security crime statistics

Pursuant to the Jeanne Clery Disclosure of Campus Security Policy and Campus Crime Statistics Act and the Pennsylvania Act of 1988, Penn State publishes a combined Annual Security and Annual Fire Safety Report (ASR). The ASR includes crime statistics and institutional policies concerning campus security, such as those concerning alcohol and drug use, crime prevention, the reporting of crimes, sexual assault and other matters. The ASR is available for review here.

EEO is the law

Penn State is an equal opportunity employer and is committed to providing employment opportunities to all qualified applicants without regard to race, colour, religion, age, sex, sexual orientation, gender identity, national origin, disability or protected veteran status. If you are unable to use our online application process due to an impairment or disability, please contact 814-865-1473.

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