Senior Principal Mechanical Engineer, Development (Sign On Bonus Available)

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

Job Description

BAE Systems is seeking a Senior Principal Mechanical Engineer to join our team in Nashua, NH!

“We Protect Those Who Protect Us®” is our mission, and we’re looking for engineers who share our passion in developing a full range of first-of-its-kind technologies and equipment to protect air, land, and naval warfighters on all fronts. At our Nashua, New Hampshire site, the Countermeasure & Electromagnetic Attack Solutions team provides next-generation threat detection and countermeasure solutions that provide unparalleled electronic warfare capabilities to enhance mission survivability.

If you are an individual who thrives in Agile hardware development environments, then we are interested in hearing from you! This exciting role spans the full product lifecycle - business capture, development, production, testing, sustaining - for a variety of complex defense products and technologies. You will collaborate closely with other electrical, mechanical, software, firmware and test engineers, as well as product managers and stakeholders to develop excellent solutions.

We are looking for candidates who are detail-oriented, possess strong analytical skills, and have a passion for continuous improvement. You will be responsible for ensuring the performance, quality and reliability of electronic products through rigorous design, analysis and testing. In addition, the ideal candidate has experience with, and is a strong advocate of, Agile hardware development, risk-reduction prototyping, and requirements-driven design and verification.

Typical Duties Assigned To This Position

• 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

The ideal candidate will thrive in a learning environment that encourages leadership and technical growth.

Please note that this position is a Hybrid work location, and work will be performed onsite and also remote.

Current BAE Systems employees are ineligible for sign-on bonuses.

Required Education, Experience, & Skills

• Bachelor's degree in Mechanical Engineering
• 8+ years (or 6+ years with MS ME) designing, testing, and troubleshooting high-reliability embedded systems
• Demonstrated understanding of mechanical principles, test methodologies, and the ability to work with advanced test equipment and cutting-edge technology
• Strong “hands‑on” laboratory experience with instrumentation, equipment, and processes
• Active DOD Security Clearance

Preferred Education, Experience, & Skills

• Possess an understanding in the application of heat transfer principles, strength of materials, materials selection, design for vibration environments and the ability to apply those principles to unique mechanical design challenges
• Experience with mechanical engineering tools for design and analysis, including ANSYS Workbench/Mechanical, PTC Creo, MATLAB/Simulink, Siemens NX, ANSYS Icepak
• Familiarity with design, analysis, and manufacturing standards associated with complex multilayer rigid and rigid‑flex CCAs
• Knowledge of engineering development processes for aero/defense industry, including designing and testing to ASTM, SAE, DO, MIL-STD-810
• Experience being a lead within a cross-fucntional engineering team to develop prime mission equipment or test equipment through various stages of development cycles
• A self‑starter with Agile hardware development experience
• Exceptional degree of ingenuity, creativity and resourcefulness.
• Control account management experience
• Experience with LRIP / FRP, specially electronics manufacturing and test methodologies
• Familiarity with AS9145 compliant processes
• Strong written and verbal communication skills

Pay Information

Full-Time Salary Range: $132962 - $226035

Please note: This range is based on our market pay structures. However, individual salaries are determined by a variety of factors including, but not limited to: business considerations, local market conditions, and internal equity, as well as candidate qualifications, such as skills, education, and experience.

Employee Benefits

• Health, dental, and vision insurance; health savings accounts; a 401(k) savings plan; disability coverage; and life and accident insurance.
• We also have an employee assistance program, a legal plan, and other perks including discounts on things like home, auto, and pet insurance.
• Our leave programs include paid time off, paid holidays, as well as other types of leave, including paid parental, military, bereavement, and any applicable federal and state sick leave.
• Employees may participate in the company recognition program to receive monetary or non‑monetary recognition awards.
• Other incentives may be available based on position level and/or job specifics.

About BAE Systems Electronic Systems

BAE Systems, Inc. is the U.S. subsidiary of BAE Systems plc, an international defense, aerospace and security company which delivers a full range of products and services for air, land and naval forces, as well as advanced electronics, security, information technology solutions and customer support services. Improving the future and protecting lives is an ambitious mission, but it’s what we do at BAE Systems. Working here means using your passion and ingenuity where it counts – defending national security with breakthrough technology, superior products, and intelligence solutions. As you develop the latest technology and defend national security, you will continually hone your skills on a team—making a big impact on a global scale. At BAE Systems, you’ll find a rewarding career that truly makes a difference. Electronic Systems (ES) is the global innovator behind BAE Systems’ game‑changing defense and commercial electronics. Exploiting every electron, we push the limits of what is possible, giving our customers the edge and our employees opportunities to change the world. Our products and capabilities can be found everywhere – from the depths of the ocean to the far reaches of space. At our core are more than 14,000 highly talented Electronic Systems employees with the brightest minds in the industry, we make an impact – for our customers and the communities we serve.