Senior Mechanical Engineer - Thermal & Rugged Electronics

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

Job summary

Mercury Systems Chantilly, VA is seeking a mechanical engineer with 4+ years of experience to join a collaborative engineering team focused on electronics production. You will design, analyze, and test rugged subsystems and servers, emphasizing cooling and thermal management, with hands-on involvement across packaging, layout, and assembly.

The role requires a Bachelor’s degree in mechanical/aerospace engineering, SolidWorks proficiency, and experience with manufacturing processes.

Qualifications

• Bachelor's degree or equivalent in mechanical or aerospace engineering or related technical field.
• Typically requires a minimum of 4 years of relevant experience.
• Strong understanding of heat transfer and thermal management.
• General knowledge of conventional and advanced manufacturing, including additive manufacturing.
• Experience with 3D CAD software such as SolidWorks.
• Familiarity with material control processes and related tools (Agile, Oracle, EPDM).
• Excellent organizational and verbal/written communication skills.
• Ability to work in a fast-paced, multi-disciplinary environment.
• Position may require government security clearance in the future; U.S. citizens only.

Responsibilities

• Mechanical packaging design for electronic subsystems and servers, including ECAD support and BOM management.
• Collaborate with Hardware, Manufacturing, Quality, and Procurement teams daily.
• Lead products from concept through integration, test, and production release.
• Design mechanical hardware for rugged military applications.
• Create complex models and drawings using SolidWorks.
• Support verification testing (thermal, airflow, vibration, environmental tests).
• Drive procurement of prototype materials to verify form, fit, and function.
• Draft test plans, inspection reports, and change requests (ECRs/ECOs).

Skills

Heat transfer

Thermal management

3D CAD

SolidWorks

Agile

Documentation

Communication

Organization

Security clearance (future)

Education

Bachelor's degree in mechanical or aerospace engineering

Tools

SolidWorks

PDM/EPDM

Oracle

Agile

Job description

Mercury Systems Chantilly, VA is seeking a mechanical engineer with 4+ years of experience to join a collaborative engineering team focused on electronics production. You will design, analyze, and test rugged subsystems and servers, emphasizing cooling and thermal management, with hands-on involvement across packaging, layout, and assembly.

The role requires a Bachelor’s degree in mechanical/aerospace engineering, SolidWorks proficiency, and experience with manufacturing processes.