Senior Principal Mechanical Engineer, Defense Hardware

BAE Systems, Inc.; Nashua (NH); Hybrid; USD 133,000 - 226,000; Full time

Benefits offered by this job

Health, dental, and vision insurance

401(k) savings plan

Disability coverage

Life and accident insurance

Employee assistance program

Paid time off and holidays

Job summary

BAE Systems, Inc. seeks a Senior Principal Mechanical Engineer to join our Nashua, NH team. You will lead mechanical designs for complex defense systems, develop 3D CAD models with GD&T, and perform rigorous thermal and structural analyses across the product lifecycle.

The role emphasizes Agile hardware development, prototype testing, and cross‑functional collaboration with electrical, software, and test teams. The hybrid work model combines onsite and remote activities.

Qualifications

• Bachelor's degree in Mechanical Engineering.
• 8+ years designing, testing, and troubleshooting high-reliability embedded systems.
• Demonstrated understanding of mechanical principles, test methodologies, and the ability to work with advanced test equipment.
• Strong hands-on laboratory experience with instrumentation, equipment, and processes.
• Active DOD Security Clearance.

Responsibilities

• Lead mechanical engineering designs, development, integration/test, and production of complex and dynamic military systems.
• Generate 3D solid models, drawings, and documentation utilizing GD&T principles.
• Perform tolerance analyses to assure fit & function.
• Perform thermal, structural/stress, and modal/vibration analyses.
• Assess designs against environmental requirements.
• Develop prototypes and conduct test and verification efforts.
• Partner with other engineering disciplines and operations personnel to develop solutions that adhere to DTUPC, DFT, and DFM requirements.
• Support resolution of technical issues discovered during manufacture and test of deliverable hardware.
• Evaluate and troubleshoot mechanical faults and issues, assessing test failures for root cause, identifying disposition/corrective actions.
• Design test equipment to ensure the performance and integrity of manufactured products.
• Participate in requirements development, performing technical trade studies, and evaluating technology insertion/upgrades.
• Develop and execute test plans, which includes the integration of test solutions, and provide detailed reports on test results.
• Participate in new business capture.

Skills

Agile hardware development

Cross-functional leadership

Analytical skills

Hands-on laboratory experience

Active DoD Security Clearance

Education

Bachelor's degree in Mechanical Engineering

Tools

ANSYS Workbench/Mechanical

PTC Creo

MATLAB/Simulink

Siemens NX

ANSYS Icepak

Job description

BAE Systems, Inc. seeks a Senior Principal Mechanical Engineer to join our Nashua, NH team. You will lead mechanical designs for complex defense systems, develop 3D CAD models with GD&T, and perform rigorous thermal and structural analyses across the product lifecycle.

The role emphasizes Agile hardware development, prototype testing, and cross‑functional collaboration with electrical, software, and test teams. The hybrid work model combines onsite and remote activities.