Senior Mechanical Design Engineer

Leonardo Electronics US Inc; Tucson (AZ); On-site; USD 120,000 - 180,000; Full time

Job summary

Leonardo Electronics US Inc. is seeking a Senior Mechanical Design Engineer to drive design and analysis of advanced diode laser systems. The role blends hands‑on prototype work in our lab with collaboration across customers and cross‑functional teams, ensuring robust, producible solutions.

You will mentor engineers, manage design reviews, and contribute to product excellence from concept through production transfer in a fast‑paced environment.

Qualifications

• Bachelor of Science in Mechanical Engineering from an ABET accredited institution.
• 6+ years of impactful engineering experience with increasing responsibility and independent thinking.
• Hands-on development in a cleanroom environment up to 50% of time.

Responsibilities

• Lead design and rigorous analysis of complex mechanical components and assemblies.
• Spend substantial time on hands-on prototype development and testing in cleanroom and lab settings.
• Mentor junior engineers and guide project priorities to success.
• Collaborate with Program Managers to maintain scope and budget, and transfer designs to production.

Skills

Hands-on development

Thermal design

CAD design

ANSYS analysis

Mentorship

Education

B.S. in Mechanical Engineering (ABET-accredited)

Tools

SolidWorks

ANSYS

Job description

If you are unable to complete this application due to a disability, contact this employer to ask for an accommodation or an alternative application process.

Senior Mechanical Design Engineer

S Tucson, AZ, US

3 days ago Requisition ID: 1492

Forge the Future of Laser Technology: Senior Mechanical Design Engineer

Job Purpose:

Are you a visionaryMechanical Design Engineer driven to innovate and deliver groundbreaking solutions? Do you thrive in a dynamic, hands‑on environment where your expertise directly impacts cutting‑edge technology? Leonardo is seeking a Senior Mechanical Design Engineer to join our elite team and lead the charge in developing the next generation of diode laser systems.

This isn't just a desk job. You'll operate at the forefront of innovation, with approximately 50% of your time dedicated to hands‑on development in our cleanroom and laboratory facilities. We're looking for an individual who embraces the challenge of transforming concepts into reality, moving seamlessly between sophisticated design work and the tangible satisfaction of prototype development and testing.

As a Senior Mechanical Design Engineer, you'll be instrumental in shaping the future of our products, from initial concept through to final delivery. This is a highly collaborative role where you'll directly engage with customers, cross‑functional internal teams, and external partners, ensuring superior results. You'll also have the opportunity to mentor and guide less experienced engineers, cultivating talent and leading project priorities to success.

Duties:

• Pioneering Design & Analysis: Lead the design and rigorous analysis of complex mechanical components and assemblies, including:
  • High‑performance Heatsinks and Heat Exchangers for optimized thermal management.
  • Precision Optical Assemblies critical for laser performance.
  • Robust Medical, Military, Commercial, and Scientific grade assemblies meeting stringent industry standards.
  • Innovative Opto‑Mechanical and Electro‑Mechanical Assemblies.
  • Advanced Direct Diode Laser Sources, Fiber Coupled Laser Systems, and supporting Tooling and Test System Design.
• Problem‑Solving Mastery: Tackle the toughest engineering challenges with a blend of sound engineering principles and "out‑of‑the‑box" thinking.
• CAD & Simulation Excellence: Become the master of 3D and 2D CAD design and detailing using SolidWorks (CSWP highly desired), adhering to ANSI Y14.5M standards and GD&T.
• Leverage ANSYS (Mechanical & Fluent expertise a significant plus) and other advanced analytical tools for comprehensive design validation, ensuring peak performance and reliability.
• Leadership & Mentorship: Guide junior engineers and technicians, driving project success and fostering a culture of technical excellence.
• Strategic Project Management: Collaborate closely with Program Managers to maintain project scope and budget.
• Seamless Integration: Ensure successful product development transfer to production with Product Engineers.
• Impactful Communication: Present complex design reviews with clarity and conviction to both internal stakeholders and external customers.
• Hands‑On Innovation:Dive deep into prototype assembly and debugging, working alongside a multidisciplinary team. Your hands‑on experience will include:
  • Advanced solder reflow and hierarchy techniques, including micro component assembly tooling.
  • Developing pump and cooling systemsfor complex coolant systems.
  • Building and verifying laser testing equipment for both prototype development and production implementation.
  • Constructing and validating assembly tooling for precision micro‑component and micro‑optics assembly.
• Driving Advancements: Spearhead research, development, and implementation of new mechanical design technologies to significantly enhance power output, reliability, efficiency, SWaP (Size, Weight, and Power), and robustness of our laser arrays and systems.

Skills/Qualifications:

• A Bachelor of Science degree in Mechanical Engineering from an ABET accredited institution.
• A minimum of 6 years of impactful experience in a related engineering field, demonstrating a clear history of increasing responsibility and independent thinking, culminating in the successful design and implementation of complex products.
• Proven expertise with hands‑on development and prototype builds, including the ability to thrive in a cleanroom environment up to 50% of the time.
• A desire to own products from concept to completion, embracing the full lifecycle of innovation.
• Exceptional understanding of thermal design, particularly with heatsinks and heat exchangers, across various fluids and materials.
• Experience in designing mm to micron level components, assemblies, and tooling.
• Familiarity with technologies for manufacturing precision mechanical components (metals, ceramics, glass) in low to medium volumes.
• A practical and applied knowledge of ANSI Y14.5-2018from creating your own 2D drawings.
• Prior experience with laser systems (diode arrays, solid‑state, fiber) and some knowledge of optics is highly preferred.
• Experience with composite metals for thermal interfaces and metal additive manufacturing in a production environment.

Leonardo is an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, national origin, sexual orientation, gender identity, disability status, protected veteran status, or any other characteristic protected by law.

[NOTE: The above statements are intended to describe the general nature and level of work being performed by people assigned to this classification. They are not to be construed as an exhaustive list of all responsibilities, duties, and skills required of personnel so classified. All personnel may be required to perform duties outside of their normal responsibilities from time to time, as needed.]

Here are the hiring process steps and what you can expect from us:

Step 1: Application Review:

Upon submitting your application, it is made available to the recruitment team to review and ensure you meet the basic qualifications.

Step 2: Interview:

If you have been identified to move forward in the process, you may be invited to participate in a one‑on‑one or panel interview. The interview format can be a phone call, in‑person, or virtual meeting.

Step 3: Offer:

If you reach this stage of the interview process, congratulations! ...