Senior/Principal Mechanical Engineer

USMAT, Inc.; Natick (MA); On-site; USD 120,000 - 190,000; Full time

Job summary

USMAT, Inc. is seeking a hands-on Senior / Principal Mechanical Engineer to design and build next‑generation sensing platforms, robotic systems, and innovative thermal management technologies.

You will own concepts from initialization through deployment, work across mechanical, electrical, and control disciplines, and collaborate with a small, highly technical team to bring hardware from idea to production.

Qualifications

• Ph.D. in Mechanical Engineering or equivalent; exceptional B.S./M.S. considered.
• 5+ years of relevant industry or advanced research experience preferred.
• Hands-on experience designing and building physical systems.

Responsibilities

• Design and develop robotic/mechanical systems and motion control platforms.
• Develop thermal management solutions and cooling systems.
• Design housings, enclosures, and precision components for sensing systems.
• Perform mechanical, structural, and thermal analyses to improve performance.
• Create 3D CAD models and manufacturing drawings.
• Prototype, test, and iteratively improve hardware.
• Integrate mechanics with sensors, electronics, and control systems.
• Support R&D, patents, and technical proposals.

Skills

CAD modeling

Robotics integration

Thermal management

FEA

GD&T

CNC machining

Additive manufacturing

Sensor packaging

Python/ Matlab

Education

Ph.D. in Mechanical Engineering

Tools

SolidWorks

Autodesk Inventor

Fusion 360

MATLAB

Python

Job description

USMAT, Inc. develops innovative sensing technologies, robotic systems, and advanced engineering solutions for industrial, scientific, and defense-related applications. We are seeking an exceptional, hands‑on Senior / Principal Mechanical Engineer to help design and build next-generation sensing platforms, robotic systems, innovative thermal management technologies, and other cutting‑edge systems.

This role is ideal for engineers who enjoy solving difficult technical problems, designing and building real hardware, and taking ownership from concept through deployment. You will work across multiple engineering disciplines while collaborating closely with a small, highly technical team.

At USMAT, talented engineers have the freedom to innovate, pursue new ideas, and directly shape products, technology, and company direction.

What You'll Work On

Senior / Principal Mechanical Engineer

USMAT, Inc. develops innovative sensing technologies, robotic systems, and advanced engineering solutions for industrial, scientific, and defense-related applications. We are seeking an exceptional, hands‑on Senior / Principal Mechanical Engineer to help design and build next-generation sensing platforms, robotic systems, innovative thermal management technologies, and other cutting‑edge systems.

This role is ideal for engineers who enjoy solving difficult technical problems, designing and building real hardware, and taking ownership from concept through deployment. You will work across multiple engineering disciplines while collaborating closely with a small, highly technical team.

At USMAT, talented engineers have the freedom to innovate, pursue new ideas, and directly shape products, technology, and company direction.

• Design and develop robotic and electromechanical systems, including mechanisms, actuators, precision assemblies, and motion control platforms
• Develop innovative thermal management solutions, including heat transfer, cooling systems, and high-temperature applications
• Design mechanical structures, housings, enclosures, and precision components for advanced sensing and instrumentation systems
• Perform mechanical, structural, and thermal analysis to optimize system performance, reliability, and manufacturability
• Develop detailed 3D CAD models, engineering drawings, and manufacturing documentation
• Design, fabricate, assemble, and test functional prototypes using CNC machining, additive manufacturing, and other fabrication techniques
• Integrate mechanical components with sensors, electronics, actuators, and control systems
• Develop experimental test fixtures, laboratory equipment, and specialized engineering tools
• Prototype, test, troubleshoot, and iteratively improve hardware systems
• Participate in full product development cycles from initial concept through testing, validation, and deployment
• Contribute to new technology concepts, patents, technical proposals, and R&D initiatives

Why Engineers Like Working Here

• High technical ownership and autonomy
• Work on challenging, multidisciplinary engineering problems
• Small, highly capable team with rapid decision-making
• Opportunity to influence both technology and product direction
• Broad exposure across mechanical design, robotics, thermal systems, sensing, and systems engineering
• Direct involvement in design, fabrication, assembly, and testing rather than being limited to a narrow engineering function
• Fast‑moving environment where strong contributions have immediate impact
• Significant opportunity for technical and professional growth

Requirements

• U.S. Citizenship
• Ability to independently execute complex technical work with high-quality results
• Excellent written and verbal communication skills
• Strong technical leadership and problem‑solving abilities
• Demonstrated hands‑on engineering skills and experience building and testing physical systems
• Passion for developing innovative technologies and turning ideas into working hardware

Qualifications

• Ph.D. in Mechanical Engineering or a closely related engineering field (exceptional B.S. or M.S. will be considered)
• 5+ years of relevant industry or advanced research experience preferred
• Strong background in several of the following:
• Mechanical design and 3D CAD modeling (SolidWorks, Autodesk Inventor, Fusion 360, or equivalent)
• Robotics, mechanisms, actuators, and electromechanical systems
• Thermal management, heat transfer, and fluid dynamics
• Structural analysis, finite element analysis (FEA), and mechanical simulation
• Precision mechanical design, tolerancing, and GD&T
• CNC machining, additive manufacturing, and rapid prototyping
• Materials selection, manufacturing processes, and design for manufacturability
• Sensor packaging, environmental sealing, and mechanical integration
• Experimental testing, instrumentation, and mechanical characterization
• Demonstrated ability to solve challenging technical problems effectively and efficiently
• Self-driven, proactive, detail-oriented, and highly accountable
• Ability to work independently while collaborating effectively with a multidisciplinary team
• Comfortable operating in a fast‑paced and dynamic R&D environment

Bonus Experience

• Computational fluid dynamics (CFD) and advanced thermal simulation
• High‑temperature materials, thermal protection systems, and heat exchangers
• Underwater systems, marine robotics, or pressure‑resistant mechanical designs
• Precision instrumentation, acoustic sensors, or scientific equipment
• Robotics, motion control, servo systems, and actuator integration
• Advanced materials, composites, and specialized manufacturing processes
• Design and operation of experimental test systems and laboratory equipment
• Experience with embedded electronics, sensors, and control system integration
• Python, MATLAB, or other engineering analysis and automation tools
• Experience developing new technologies under government‑funded R&D programs, including SBIR/STTR
• Technical proposal development, patents, and technology commercialization

Ideal Candidate

You are the kind of engineer who likes building things that have never existed before. You are curious, highly capable, practical, and motivated by solving hard technical problems.

You are equally comfortable developing a sophisticated CAD model, performing engineering calculations, machining or assembling a prototype, and troubleshooting a system in the laboratory.

You understand that successful engineering requires more than theoretical analysis or elegant designs. You take pride in building systems that actually work.

You enjoy moving quickly, learning across disciplines, and taking ownership of challenging projects from concept to functional hardware. You thrive in an environment where creativity, technical rigor, initiative, and results matter more than organizational hierarchy.

If you are an exceptional mechanical engineer who wants to invent, design, build, and test technologies that push the boundaries of what's possible, we'd like to hear from you.