Senior Mechanical Engineer - Rugged Systems & PCB Packaging

Mercury Systems; Torrance (CA); On-site; USD 98,000 - 205,000; Full time

Benefits offered by this job

Bonus opportunities

Health, life and disability insurance

401(k) retirement plan

Stock purchase plan

Tuition reimbursement

LinkedIn Learning access

Headspace

Virgin Pulse

Job summary

Mercury Systems in Torrance, CA, seeks a principal level mechanical engineer to design, analyze, and test rugged subsystems and complex PCB assemblies for aerospace and defense applications.

You will lead mechanical packaging, perform thermal/structural analyses, develop BOMs, and mentor junior engineers in a fast-paced multidisciplinary team. Hybrid/onsite, with comprehensive benefits and security clearance eligibility.

Qualifications

• Bachelor's degree in mechanical or aerospace engineering.
• Typically requires a minimum of 6 years of relevant mechanical engineering experience.
• Familiarity with GD&T, ASME Y14.5, Y14.100.
• Experience and understanding of PWA/CCA design and associated manufacturing processes.
• Proven experience designing electronics packaging for severe environments, including MIL-STD-810.
• Proficiency with 3D CAD software such as SolidWorks or CREO.
• Broad knowledge of both conventional and advanced manufacturing techniques, including machining and post-processing for CCAs and metal components.
• Strong foundational understanding of heat-transfer design principles and dynamic system design for shock and random vibration environments.
• Familiarity with configuration management and material control processes, including routers, work instructions, and related tools i.e. Agile, Oracle, EPDM.
• This role requires the ability to obtain and maintain a U.S. government security clearance; U.S. citizenship is required.

Responsibilities

• Lead products through the full lifecycle; from concept development to integration, testing, and production release.
• Perform mechanical engineering activities for rugged subsystems and complex PCB assemblies, including mechanical packaging, connector selection, cable and label design, prototype inspection and assembly, environmental testing, and supporting hardware documentation procurement
• Collaborate closely with cross-functional partners such as Hardware/Electrical Engineering, Manufacturing, Quality Engineering, and Procurement
• Develop and maintain Bills of Material (BOMs/PLs) to support accurate configuration and production control
• Draft, submit, and manage Engineering Change Requests (ECRs) and Engineering Change Orders (ECOs)
• Conceptualize, design, analyze, and document mechanical hardware and systems intended for rugged military and space environments
• Conduct thermal and structural analysis and/or simulations to ensure robust mechanical and environmental performance
• Design complex fixtures to support product testing and advanced manufacturing processes
• Create detailed 3D models and engineering drawings
• Communicate design concepts and produce clear, high‑quality product documentation for diverse internal and external audiences
• Support environmental and functional design verification testing in accordance with MIL‑STD‑810 for severe operating conditions
• Provide hands‑on support during initial build validation of new designs, ensuring form, fit, and function are met
• Perform failure analysis of discrepant material in partnership with Manufacturing and Quality Engineering teams
• Develop test plans, inspection reports, and associated documentation in support of verification and validation activities
• Mentor and train junior engineers

Skills

Mechanical engineering

GD&T

MIL-STD-810

SolidWorks/CREO

Electronics packaging

Thermal/structural analysis

BOM management

ECN/ECO processing

Mentorship

Education

Bachelor's degree in mechanical or aerospace engineering

Master's degree (preferred)

Tools

SolidWorks

CREO

EPDM

Oracle

Agile

Job description

Mercury Systems in Torrance, CA, seeks a principal level mechanical engineer to design, analyze, and test rugged subsystems and complex PCB assemblies for aerospace and defense applications.

You will lead mechanical packaging, perform thermal/structural analyses, develop BOMs, and mentor junior engineers in a fast-paced multidisciplinary team. Hybrid/onsite, with comprehensive benefits and security clearance eligibility.