Senior Principal Mechanical Engineer - Rugged Aerospace

Socket.dev; Torrance (CA); On-site; USD 120,000 - 160,000; Full time

Job summary

Mercury Systems is seeking a principal mechanical engineer to lead mechanical design for rugged subsystems and complex PCB assemblies in aerospace and defense applications. You will design, analyze, and test hardware for harsh environments, mentoring juniors and collaborating across engineering teams.

The role emphasizes experience with 3D CAD (SolidWorks/CREO), GD&T, MIL-STD-810, and climate/vibration considerations, with opportunity to influence from concept to production.

Qualifications

• Bachelor's degree in mechanical or aerospace engineering
• 6+ years of mechanical engineering experience
• Familiarity with MIL-STD-810 and rugged environments
• Experience designing electronics packaging for severe environments
• Proficient with 3D CAD software such as SolidWorks or CREO

Responsibilities

• Lead products through the full lifecycle; from concept development to integration, testing, and production release.
• Perform mechanical engineering activities for rugged subsystems and complex PCB assemblies, including mechanical packaging, connector selection, cable and label design, prototype inspection and assembly, environmental testing, and supporting hardware documentation procurement
• Collaborate closely with cross‑functional partners such as Hardware/Electrical Engineering, Manufacturing, Quality Engineering, and Procurement
• Develop and maintain Bills of Material (BOMs/PLs) to support accurate configuration and production control
• Draft, submit, and manage Engineering Change Requests (ECRs) and Engineering Change Orders (ECOs)
• Conceptualize, design, analyze, and document mechanical hardware and systems intended for rugged military and space environments
• Conduct thermal and structural analysis and/or simulations to ensure robust mechanical and environmental performance
• Design complex fixtures to support product testing and advanced manufacturing processes
• Create detailed 3D models and engineering drawings
• Communicate design concepts and produce clear, high‑quality product documentation for diverse internal and external audiences
• Support environmental and functional design verification testing in accordance with MIL‑STD‑810 for severe operating conditions
• Provide hands‑on support during initial build validation of new designs, ensuring form, fit, and function are met
• Perform failure analysis of discrepant material in partnership with Manufacturing and Quality Engineering teams
• Develop test plans, inspection reports, and associated documentation in support of verification and validation activities
• Mentor and train junior engineers

Skills

GD&T

ASME Y14.5

Y14.100

MIL-STD-810

Electronics packaging

Thermal design

Vibration design

Configuration management

Agile

Oracle

EPDM

6Sigma

Celsius

SC Stream

SC Flow

SolidWorks Simulation

Femap

NASTRAN

Education

Bachelor's degree in mechanical or aerospace engineering

6+ years of mechanical engineering experience

Master's degree in mechanical or aerospace engineering

Tools

SolidWorks

CREO

SolidWorks Simulation

Femap

NASTRAN

EPDM

Oracle

Job description

Mercury Systems is seeking a principal mechanical engineer to lead mechanical design for rugged subsystems and complex PCB assemblies in aerospace and defense applications. You will design, analyze, and test hardware for harsh environments, mentoring juniors and collaborating across engineering teams.

The role emphasizes experience with 3D CAD (SolidWorks/CREO), GD&T, MIL-STD-810, and climate/vibration considerations, with opportunity to influence from concept to production.