Senior Mechanical Engineer - Electronics Packaging & Thermal

mercurysystemscareers; Hudson, Andover (NH, MA); On-site; USD 120,000 - 180,000; Full time

Job summary

Mercury Systems is seeking a principal mechanical engineer to design, analyze, and test electronic subsystems for rugged aerospace/defense applications. You will lead from concept through production, creating SolidWorks models and detailed drawings while collaborating with Hardware, Manufacturing, Quality, and Procurement.

This role requires a bachelor's degree in mechanical or aerospace engineering and 6+ years in electronics packaging, with GD&T, thermal management, and additive manufacturing

Qualifications

• Bachelor’s degree in mechanical engineering, aerospace engineering, or a related technical discipline.
• Typically requires a minimum of 6+ years of related industry experience.
• Strong experience in electronics packaging, design, and processes.
• Solid understanding of structural dynamics, heat transfer, and thermal management of electronics.
• Knowledge of conventional manufacturing methods and advanced manufacturing, including additive manufacturing.
• Proficiency with 3D CAD software, preferably SolidWorks.
• Familiarity with material control processes and documentation, including routers and work instructions, as well as related systems i.e. Agile, Oracle, EPDM.
• This position is onsite in Andover, MA or Hudson, NH.

Responsibilities

• Design and develop electronic module assemblies using open standards, including mechanical packaging, printed wiring board layouts, ECAD support, connector selection, cable and label design, prototype inspection, and environmental testing.
• Perform mechanical packaging tasks for electronics integrated within larger subsystems, including backplane and cable design.
• Collaborate daily with cross-functional teams such as Hardware/Electrical Engineering, Manufacturing, Quality Engineering, and Procurement.
• Lead products from concept through design, integration, testing, and final production release.
• Conceptualize, design, develop, and analyze mechanical hardware and systems for rugged military applications, including thermal, structural, reliability, materials, and tolerance analyses.
• Design complex fixtures to support testing and advanced manufacturing processes.
• Create detailed 3D models and engineering drawings using SolidWorks.
• Conduct peer reviews of designs, analyses, and engineering documentation.
• Communicate and present technical concepts and product documentation to diverse internal and external audiences.
• Support product verification testing, including thermal, airflow, vibration, mechanical shock, humidity, and environmental stress screening.
• Coordinate procurement of prototype materials and validate form, fit, and function.
• Perform failure analysis of discrepant materials in partnership with Manufacturing and Quality teams.
• Develop test plans, inspection reports, and documentation for verification and validation activities.
• Create and maintain Bills of Material (BOMs/PLs).
• Draft and manage Engineering Change Requests (ECRs) and Engineering Change Orders (ECOs).
• Support sustaining engineering and legacy product efforts.

Skills

electronic packaging

structural dynamics

heat transfer

thermal management

SolidWorks

3D CAD

leadership

cross-functional collaboration

Education

Bachelor's degree

Tools

SolidWorks

EPDM

Agile

Oracle

Job description

Mercury Systems is seeking a principal mechanical engineer to design, analyze, and test electronic subsystems for rugged aerospace/defense applications. You will lead from concept through production, creating SolidWorks models and detailed drawings while collaborating with Hardware, Manufacturing, Quality, and Procurement.

This role requires a bachelor's degree in mechanical or aerospace engineering and 6+ years in electronics packaging, with GD&T, thermal management, and additive manufacturing