Senior Mechanical Engineer

Maxtena Inc; Germantown (MD); On-site; USD 110,000 - 150,000; Full time

Job summary

Maxtena Inc. is seeking a Senior Mechanical Engineer to lead the design, development, analysis, and testing of mechanical systems for advanced electronics.

This hands-on role drives the full product lifecycle from concept through production, ensuring compliance with quality, regulatory, and EMI/RF requirements. You will mentor junior engineers and collaborate across functions to deliver robust, manufacturable solutions.

Qualifications

• U.S. Citizen able to obtain Secret Clearance.
• 8+ years of mechanical design and engineering experience (electromechanical design preferred).
• Experience in aerospace/defense RF systems or high-precision manufacturing is a plus.
• Proficiency in CAD, FEA, and thermal analysis tools.
• Deep understanding of GD&T and tolerance analysis.
• Experience with structural and/or thermal analysis tools (SolidWorks Simulation/ ANSYS).
• Strong materials knowledge and manufacturing process understanding.
• Excellent problem-solving, communication, and documentation skills.

Responsibilities

• Lead mechanical design of small, complex electronics enclosures from concept through production.
• Design and optimize EMI/RF shielding, including enclosure seams, gaskets, interfaces, and grounding.
• Develop RF-transparent radome and RF window designs balancing EM performance with mechanical strength and manufacturability.
• Develop mechanical and thermal solutions for high-density electronics (conduction cooling, heat sinks, thermal interfaces).
• Design for demanding environmental conditions (water ingress, dust, vibration, corrosion, outdoor exposure).
• Mentor junior mechanical engineers and provide technical leadership on complex design problems.
• Create detailed 3D CAD models, drawings, assemblies, and documentation; collaborate with prototype shops and suppliers.
• Participate in environmental, EMI/EMC, RF, thermal, and mechanical qualification testing.

Skills

SolidWorks

FEA & Thermal

GD&T

Mechanical Drawings

Cross-functional teamwork

Technical Leadership

Documentation

Problem Solving

3D Printing

Machining Processes

Education

Bachelor's in Mechanical Engineering

Master's degree preferred

Tools

SolidWorks

SolidWorks Simulation

ANSYS

Job description

The Senior Mechanical Engineer is responsible for leading the design, development, analysis, and testing of mechanical systems and components. This is a hands on role, that is essential in leading full product lifecycle from concept through production and ensures designs meet technical, quality, and regulatory requirements. The Senior Mechanical Engineer collaborates cross-functionally, mentors junior engineers, and contributes to continuous improvement and innovation initiatives.

Essential Duties and Responsibilities:

• Lead the mechanical design of small, complex electronics enclosures from concept through production.
• Design and optimize EMI/RF shielding, including enclosure architecture, seams, joints, gaskets, interfaces, and grounding strategies.
• Develop RF-transparent radome and RF window designs, balancing electromagnetic performance with mechanical strength, environmental durability, manufacturability, and appearance.
• Develop mechanical and thermal solutions for high-density electronics, including conduction cooling, heat spreading, heat sinks, thermal interfaces, and passive cooling strategies.
• Design for demanding environmental conditions, including water ingress, dust, vibration, shock, temperature extremes, corrosion, and outdoor exposure.
• Select appropriate materials, coatings, finishes, seals, gaskets, adhesives, and joining methods for demanding applications.
• Perform mechanical analysis and engineering calculations, including thermal, structural, tolerance, and vibration analysis as appropriate.
• Create detailed 3D CAD models, drawings, assemblies, and engineering documentation.
• Work directly with prototype shops, suppliers, and manufacturing partners to develop and refine designs.
• Build and test prototypes, investigate failures, and drive design improvements.
• Participate in environmental, EMI/EMC, RF, thermal, and mechanical qualification testing.
• Mentor junior mechanical engineers and provide technical leadership on complex design problems.
• Contribute to engineering standards, design methodologies, and product development processes.

Preferred Qualifications:

• Must be a U.S. Citizen with the ability to obtain Secret Clearance.
• Bachelor’s degree in Mechanical Engineering or related field, Master’s degree preferred.
• 8+ years of mechanical design and engineering experience, developing & designing electromechanics experience preferred.
• Proficiency in CAD software (SolidWorks) FEA and thermal analysis tools.
• Demonstrated understanding of GD&T, tolerance analysis, mechanical drawings, and configuration-controlled engineering.
• Experience with structural and/or thermal analysis tools, such as Solidworks Simulation or ANSYS.
• Strong understanding of materials, manufacturing processes, and mechanical systems.
• Excellent problem-solving, communication, and documentation skills.
• Experience in aerospace, defense, RF systems, or high-precision manufacturing.
• Demonstrated hands on experience with die casting, CNC machining, sheet metal, composite molding and additive manufacturing.
• Advanced proficiency with full cycle 3D printer protype builds.
• Demonstrated ability working in cross-functional development teams

Maxtena is an Equal Opportunity Employer. All applicants applying for U.S. job openings must be authorized to work in the United States.