Senior Mechanical Engineer

chaosindustries; El Segundo (CA); On-site; USD 120,000 - 160,000; Full time

Benefits offered by this job

Health benefits

Job summary

CHAOS Industries seeks a Senior Mechanical Engineer to design and integrate ruggedized sensor systems and avionics for dual-use aerospace and defense applications. You will lead 3D CAD development, documentation, and interface control across multidisciplinary teams on complex assemblies.

The role spans concept to qualification, involving structural/thermal analysis, prototyping, testing, and DFMA. On-site in El Segundo, CA, with a focus on fast-paced delivery and mission-critical performance.

Qualifications

• Bachelor's degree in Mechanical Engineering or related discipline.
• 4+ years of mechanical design and integration experience for aerospace/defense applications.
• Proficiency with CAD tools (SolidWorks) and producing production-ready drawings.
• Ability to obtain and maintain a U.S. security clearance.
• Experience with RF, avionics, power electronics integration.

Responsibilities

• Design ruggedized electronic hardware, sensor systems, avionics, enclosures, structures, mechanisms, and related support equipment.
• Develop and maintain 3D CAD models, complex assemblies, detailed drawings, installation documentation, and ICDs.
• Own the design and documentation of assigned components, assemblies, and mechanical subsystems.
• Track and manage size, weight, and mechanical allocations for electronic assemblies and integrated hardware.
• Perform first-order structural and thermal analyses, hand calculations, requirements analysis, and design verification activities.
• Support prototype fabrication, assembly, mechanical integration, testing, qualification, fit-check, installation, alignment, and troubleshooting activities.
• Collaborate with mechanical, electrical, RF, power, manufacturing, systems engineering, customers, suppliers, and platform providers to resolve integration challenges.
• Support make/buy evaluations, production transition, DFMA, configuration control, fielding, and sustainment activities.
• Participate in design reviews, failure investigations, and other technical decision-making activities.

Skills

Mechanical CAD

SolidWorks

GD&T

Thermal analysis

Prototype fabrication

Education

Bachelor's degree in Mechanical Engineering

Master's degree in Mechanical Engineering

Tools

NASTRAN

ABAQUS

ANSYS

COMSOL

Job description

CHAOS Industries is redefining modern defense with a multi-product portfolio that gives the ultimate advantage-domain dominance. The company's products are powered by Coherent Distributed Networks (CDN™), empowering warfighters, commercial air operators, and border protection teams to act faster, adapt rapidly, and stay ahead of evolving threats.

CHAOS Industries was founded in 2022 and has raised a total of $1 billion in funding from leading investors, including 8VC, Accel, and Valor Equity Partners. The company is headquartered in Los Angeles, with offices in Washington, D.C., San Francisco, San Diego, Seattle, and London. For more information, please visit www.chaosinc.com.

Role Overview:

CHAOS is seeking a Senior Mechanical Engineer to support the hands‑on design, development, packaging, integration, and qualification of ruggedized sensor systems, avionics, electronic hardware, and related mission‑critical systems for dual‑use aerospace and defense applications. The ideal candidate brings strong mechanical design and CAD expertise, experience with complex assemblies and integrated systems, and demonstrated prototyping, analysis, and problem‑solving skills.

The position spans the product lifecycle from concept development and architecture through detailed design, analysis, prototyping, qualification testing, production, fielding, and sustainment. Design challenges may include structures, enclosures, mechanisms, electromechanical hardware, thermal solutions, support equipment, and other systems deployed across land‑, sea‑, and air‑based platforms.

This is a full‑time, on‑site position in El Segundo, CA.

Responsibilities:

• Design ruggedized electronic hardware, sensor systems, avionics, enclosures, structures, mechanisms, and related support equipment in accordance with program requirements and applicable standards
• Develop and maintain 3D CAD models, complex assemblies, detailed drawings, installation documentation, and interface control documents (ICDs)
• Own the design and documentation of assigned components, assemblies, and mechanical subsystems
• Track and manage size, weight, and mechanical allocations for electronic assemblies and integrated hardware
• Perform first‑order structural and thermal analyses, hand calculations, requirements analysis, and design verification activities
• Support prototype fabrication, assembly, mechanical integration, testing, qualification, fit‑check, installation, alignment, and troubleshooting activities
• Collaborate with mechanical, electrical, RF, power, manufacturing, systems engineering, customers, suppliers, and platform providers to resolve integration challenges
• Support make/buy evaluations, production transition, Design for Manufacturing and Assembly (DFMA), configuration control, fielding, and sustainment activities
• Participate in design reviews, failure investigations, and other technical decision‑making activities

Minimum Requirements:

• Bachelor's degree in Mechanical Engineering or a related discipline
• 4+ years of relevant experience in mechanical design and integration of electronic hardware for aerospace, defense, or similar applications
• Strong proficiency with mechanical CAD tools, such as SolidWorks or equivalent, including complex parts and assemblies
• Experience producing and reviewing production‑ready mechanical drawings and documentation
• Understanding of mechanical interfaces, tolerancing, alignment, installation practices, GD&T, tolerance analysis, and configuration‑controlled documentation
• Experience designing or integrating mechanical hardware for RF, avionics, power electronics, embedded computing, or similar products
• Familiarity with structural analysis methods, including hand calculations and FEA
• Experience supporting prototype builds, integration, testing, or qualification activities
• Familiarity with ruggedized hardware and applicable environmental requirements
• Strong problem‑solving skills, attention to detail, and ability to work effectively in fast‑paced, multi‑disciplinary development environments
• Ability to obtain and maintain a U.S. security clearance

Preferred Requirements:

• Master's degree in Mechanical Engineering or a related field
• Experience supporting environmental qualification testing and analysis, including thermal cycling, vibration, and shock
• Experience with commercial FEA or multiphysics simulation tools, such as NASTRAN, ABAQUS, ANSYS, COMSOL, or similar tools
• Familiarity with military and aerospace standards, including MIL-STD-810
• Familiarity with military and aerospace connectors, such as MIL-DTL-38999, ARINC, and Micro‑D
• Experience with mechanisms, actuation systems, structures, thermal management, packaging, cable routing, connector layouts, or electromechanical integration
• Experience with additive manufacturing, CNC machining, fabrication, assembly, and prototype development
• Hands‑on experience working with machine shop and prototype lab equipment

Why CHAOS?

Health Benefits: Medical, dental, a