Senior Mechanical Engineer

Actalent; Maryland; On-site; USD 110,000 - 150,000; Full time

Job summary

Actalent seeks a Senior Mechanical Engineer to lead the development of complex electromechanical systems from concept through to full production. You will own CONOPS inputs, detailed 3D design in NX, and verification plans while guiding a multidisciplinary team.

You will manage design data in PLM/PDMS, perform hand calculations and FEA, drive design reviews and risk mitigation, and mentor junior engineers to ensure robust, high-reliability hardware.

Qualifications

• Bachelor's degree in Mechanical Engineering required.
• 5–8 years of relevant mechanical engineering experience.
• 2–3 years in lead or technical responsibility over hardware development.
• Proficient in 3D CAD design (NX preferred).
• Strong leadership and design capabilities for high-reliability products.
• Experience with FEA concepts and practical validation.
• Experience with PLM/PDMS document management.

Responsibilities

• Lead design and development of complex, high-reliability electromechanical systems from concept to production.
• Translate CONOPS into mechanical/system requirements for the team.
• Drive multi-stage design reviews and manage review gates.
• Design systems in 3D CAD and create complete models from concept to detail.
• Manage design data and configuration control in PLM/PDMS.
• Perform hand calculations and FEA to validate analyses and ensure robustness.
• Lead requirements definition, traceability, and verification activities.
• Create and maintain system design docs, CONOPS, and ICDs.
• Develop risk management plans and mitigation strategies for mechanical designs.
• Contribute to test plans and coordinate testing with QA.
• Mentor engineers and support business development through proposals.

Skills

Mechanical leadership

3D CAD design

FEA analysis

Project management

Requirements traceability

Test planning

Mentoring

Documentation

Cross-functional collaboration

Education

Bachelor's degree in Mechanical Engineering

Tools

NX CAD

PDMS/PLM systems

FEA tools

NASTRAN/FEMAP

Job description

Job Description

Job Description

Job Title: Senior Mechanical Engineer

Job Description

This Senior Mechanical Engineer role leads the development of innovative, complex electromechanical systems from initial concept through full production implementation. The position spans early system concept of operations (CONOPS), detailed mechanical design, rigorous analysis, comprehensive design reviews, and oversight of testing and validation for high-reliability, mission-critical mechanisms and electromechanical systems.

Responsibilities

• Lead the mechanical design and development of complex, high-reliability electromechanical systems from concept through production implementation.
• Participate in early systems CONOPS activities and translate operational concepts into clear mechanical and system requirements.
• Drive mechanical efforts through a structured, multi-stage design review process, including managing several periodic review gates and presenting technical content.
• Design mechanical systems and mechanisms in 3D CAD, creating complete system models from concept to detailed design.
• Use PLM/PDMS systems to manage design data, documentation, and configuration control throughout the product lifecycle.
• Analyze mechanical models and systems using computer-based finite element analysis (FEA), supported by hand calculations to validate results and ensure robustness.
• Lead requirements definition, traceability, and compliance activities, ensuring that mechanical designs meet system-level requirements.
• Plan and execute verification and validation activities for mechanical systems, including creation and maintenance of requirements verification matrices.
• Prepare and maintain comprehensive technical documentation, including system design descriptions, CONOPS documents, and interface control documents (ICDs).
• Create and maintain risk management plans, identifying technical risks and mitigation strategies for mechanical designs.
• Help develop test plans and test cases for mechanical and electromechanical systems, including environmental and functional testing.
• Manage products through test campaigns, incorporating feedback from quality and other teams to refine designs and resolve issues.
• Collaborate closely with multidisciplinary teams to ensure effective communication across system interfaces and alignment with end-user needs.
• Own development schedules and project milestone reviews, tracking progress and ensuring mechanical deliverables meet program timelines.
• Organize and run technical interchange meetings to coordinate design decisions, resolve technical issues, and align stakeholders.
• Mentor other engineers, providing technical guidance, design review feedback, and support in developing their skills and capabilities.
• Support business development activities, including contributing to proposals and providing technical input on new opportunities.
• Contribute to continuous improvement of mechanical design, analysis, and documentation practices within the engineering organization.

Essential Skills

• Bachelor's degree in Mechanical Engineering.
• Approximately 5-8 years of relevant professional mechanical engineering experience, with sufficient depth to confidently lead complex development efforts.
• At least 2-3 years of lead or technical responsibility over hardware development efforts, demonstrating ownership of design, analysis, and delivery.
• Proficiency in 3D CAD software for complete system design from concept through detailed design; experience with NX is preferred, but other CAD packages are acceptable.
• Strong mechanical leadership and technical design capabilities to serve as lead mechanical engineer on complex, high-reliability products.
• Experience designing mechanical systems and mechanisms, including mission-critical, high-reliability electromechanical systems.
• Knowledge of finite element analysis (FEA) principles, with hands-on experience performing mechanical FEA strongly preferred.
• Experience using PLM/PDMS systems for document and configuration management; Siemens-based systems are ideal, though other platforms are acceptable.
• Ability to perform and interpret hand calculations to support and validate analytical and FEA results.
• Experience with mechanical testing activities and working with test teams during development and qualification.

Additional Skills & Qualifications

• Experience performing FEA analysis using NASTRAN/FEMAP is preferred; experience with other FEA software tools is also valuable.
• Familiarity with spacecraft environmental testing systems, such as thermal vacuum, vibr