Principal Mechanical Engineer

Apera; California; On-site; USD 140,000 - 210,000; Full time

Job summary

Apera is seeking a Principal Mechanical Design Engineer to design and develop complex mechanical systems for next‑gen defense technology. You will own architecture, drive CAD modeling, analysis, prototyping, testing, and production, and mentor junior engineers.

You will translate system objectives into mechanical requirements, perform structural and thermal analyses, and contribute to ensuring performance and reliability across the development lifecycle.

Qualifications

• Bachelor's degree in Mechanical, Aerospace, Structural, or related engineering.
• 8+ years of experience across the product development lifecycle.
• Expert in SolidWorks with GD&T proficiency.
• Strong knowledge of structural mechanics, thermodynamics, mechanisms, and design fundamentals.
• Experience with basic Finite Element Analysis (FEA) and hand calculations.
• Experience assembling prototypes and first-article builds, including testing.

Responsibilities

• Own mechanical architecture and design for complex electronic systems, including RF phased-array structures.
• Lead mechanical product development from concept through CAD, prototyping, testing, and production.
• Translate system objectives into mechanical requirements and interface definitions.
• Perform structural and thermal analyses for verification and environmental qualification.
• Develop CAD models, drawings, tolerances, and GD&T per ASME Y14.5.
• Develop mechanical interconnects, including harnesses and cable assemblies.
• Evaluate emerging technologies to improve performance and reliability.
• Provide technical leadership and mentor junior engineers.

Skills

Mechanical design

Technical leadership

Prototype testing

Education

Bachelor's degree in Mechanical, Aerospace, Structural, or related engineering

Tools

SolidWorks

GD&T

FEM/FEA

Job description

Our client is a high-growth defense technology company developing advanced, software-defined directed energy systems designed to address emerging threats and support the future of national security.

We are looking for a Principal Mechanical Design Engineer to join an innovative team working at the forefront of next-generation defense technology.

As a Principal Mechanical Design Engineer, you will play a key role in the design and development of complex mechanical systems, driving engineering solutions from concept through to detailed design, integration, testing and production. This is an opportunity to tackle challenging technical problems and help deliver cutting-edge defence systems.

Key responsibilities include:

• Own mechanical architecture and design for complex electronic systems, including RF phased-array structures, enclosures, mechanisms, and mounting assemblies.
• Lead mechanical product development from initial concept through CAD design, analysis, prototyping, testing, and production.
• Translate system-level objectives into clear mechanical requirements, including load cases, weight budgets, and interface definitions.
• Perform structural and thermal analyses to support design verification and environmental qualification, including shock, vibration, and dynamic loading.
• Develop detailed CAD models, manufacturing drawings, tolerance analyses, and GD&T in accordance with ASME Y14.5.
• Develop mechanical interconnect solutions, including harnesses and cable assemblies, for large-scale integrated electronic systems.
• Evaluate and incorporate emerging technologies, tools, and design practices to improve system performance, reliability, and development efficiency.
• Provide technical leadership, present design solutions during engineering reviews, and mentor junior engineers while supporting continuous improvement.

Basic Qualifications:

• Bachelor's degree in Mechanical, Aerospace, Structural, or a closely related engineering discipline.
• 8+ years of experience in mechanical design and analysis, with ownership across the product development lifecycle.
• Expert proficiency in SolidWorks or an equivalent mechanical CAD package, with practical experience applying GD&T.
• Strong understanding of structural mechanics, thermodynamics, mechanisms, and mechanical design fundamentals.
• Experience with basic Finite Element Analysis (FEA) and structural and thermal hand calculations.
• Demonstrated ability to assemble prototypes and first-article builds, including testing, troubleshooting, and minor fabrication.

The position offers the opportunity to take significant ownership of mechanical architecture and contribute directly to the development of advanced, high-performance defense systems, helping take complex designs from early-stage concepts through testing, qualification, and production.