Senior Mechanical Engineer – Thermal & Rugged Electronics

Mercury Systems; Chantilly (VA); On-site; USD 85,000 - 120,000; Full time

Job summary

Mercury Systems in Chantilly, VA is seeking a mechanical engineer with 4+ years of experience to join a small, collaborative team focused on rugged server and electronics subsystem design. You will design, analyze, and test mechanical hardware, supporting thermal management in demanding environments.

You will use SolidWorks for modeling, contribute to DFM, BOMs, and ECRs, and collaborate across Hardware, Electrical, Manufacturing, and Quality teams to move concepts into production.

Qualifications

• Bachelor's degree or equivalent in mechanical/aerospace engineering or related field.
• Typically requires a minimum of 4 years of relevant experience.
• Understanding of heat transfer and thermal management.
• Knowledge of conventional and additive manufacturing techniques.
• Experience with 3D CAD software such as SolidWorks.
• Familiarity with material control processes and related documentation tools (Agile, Oracle, EPDM).
• Excellent organizational and verbal/written communication skills.
• Ability to work in a fast-paced, multi-disciplinary environment.
• This position requires you to have or obtain a government security clearance in the future. U.S. citizen required.

Responsibilities

• Mechanical packaging design, PCB layout support, connector selection, and prototyping inspection.
• Collaborate with Hardware, Electrical, Manufacturing, Quality Engineering, and Procurement.
• Lead concepts from design through integration, test, and production release.
• Design mechanical hardware for rugged military applications and fixture development.
• Create models and drawings using SolidWorks and related tools.
• Support product verification testing (thermal, airflow, vibration, humidity, SES).
• Drive prototype material procurement to verify form, fit, and function.
• Perform failure analysis with manufacturing and application engineering.
• Draft test plans, inspection reports, BOMs/PLs, and manage ECRs/ECOs.

Skills

3D CAD (SolidWorks)

Thermal management

Engineering documentation

Cross-functional collaboration

Education

Bachelor's degree in mechanical or aerospace engineering

Master's degree in mechanical or aerospace engineering

Tools

SolidWorks

EPDM

Agile

Oracle

Job description

Mercury Systems in Chantilly, VA is seeking a mechanical engineer with 4+ years of experience to join a small, collaborative team focused on rugged server and electronics subsystem design. You will design, analyze, and test mechanical hardware, supporting thermal management in demanding environments.

You will use SolidWorks for modeling, contribute to DFM, BOMs, and ECRs, and collaborate across Hardware, Electrical, Manufacturing, and Quality teams to move concepts into production.