Sr. Principal Mechanical Engineer - Castings - ALE

RTX; Houston (TX); On-site; USD 132,000 - 252,000; Full time

Benefits offered by this job

Medical, dental, vision benefits

401(k) matching program

Paid time off and holidays

Job summary

RTX seeks a Senior Principal Mechanical Engineer (P5) in Tucson to lead design of cast parts and producibility across missile components, collaborating with cross-functional teams.

You will mentor engineers, perform GD&T, support factories and suppliers, and ensure conformance to HWE standards and security clearances.

Qualifications

• Requires STEM degree with 10+ years of experience or advanced degree with 7+ years.
• Experience in technical leadership roles across full development lifecycle.
• Experience with aluminum casting and machining processes.
• Ability to travel domestically up to 75% for casting and machining suppliers.
• Experience leading trade studies and supporting integration and test of mechanical products.
• Proficiency with ANSI/ASME Y14.5 GD&T and tolerance analysis.
• Experience creating mechanical drawings and engineering documentation.

Responsibilities

• Mechanical design, development, and documentation of components and major end items per system requirements.
• Lead and mentor mechanical engineering teams to meet schedule, budget, and technical goals.
• Collaborate with structural/thermal analysts, materials engineering, safety, and operations to refine designs.
• Support factories and suppliers with product development, troubleshooting, and obsolescence management.
• Conduct trade studies and participate in peer reviews; resolve technical action items.
• Apply analysis results to improve designs and producibility (DFMA).
• Develop and maintain the technical data package (TDP) ensuring compliance.
• Serve as responsible engineer or subsystem lead, guiding team members with limited supervision.

Skills

Technical leadership

Aluminum casting & machining knowledge

GD&T (Geometric Dimensioning & Toleran

First Article Inspection (FAI)

Education

STEM degree

Advanced degree (MS/PhD)

Tools

CREO (Pro/E)

Job description

Date Posted: 2026-10-28

Country: United States of America

Location: US-AZ-TUCSON-9030 ~ 9030 S Rita Rd ~ BLDG 9030

Position Role Type: Onsite

U.S. Citizen, U.S. Person, or Immigration Status Requirements: Active and transferable U.S. government issued security clearance is required prior to start date. U.S. citizenship is required, as only U.S. citizens are eligible for a security clearance

Security Clearance Type: Secret - Current

Security Clearance Status: Ability to obtain INTERIM U.S. government issued security clearance is required prior to start date

Raytheon brings the strength of more than 100 years of experience and renowned engineering expertise to meet the needs of today’s mission and stay ahead of tomorrow’s threat. We deliver solutions that help our nation and allies defend freedoms and deter aggression, creating a safer, more secure world. Join us and help shape the future of aerospace and defense.

The Air Launched Effectors All Up Round (ALE AUR) Mechanical Design organization is seeking a highly experienced Senior Principal Mechanical Engineer (P5) with experience in casting technologies. This individual will provide technical direction, engineering rigor, and execution oversight focused on delivering producible, affordable, high-performance mechanical solutions aligned with program objectives, Hardware Engineering (HWE) standards, and Raytheon engineering processes.

This role drives engineering excellence, design reuse, and producibility across a large, multidisciplinary mechanical engineering team. The position requires close collaboration with Program Management, Systems Engineering, Operations, Supply Chain, and cross-discipline mechanical teams including Airframe, Mechanisms, Propulsion, Avionics, Configuration Management, Data Management, and Support Equipment within the Hardware Engineering organization.

What You Will Do:

• Perform mechanical design, development, and documentation of components, sub-assemblies, and major end items in accordance with system requirements.
• Lead and mentor mechanical engineering teams while meeting schedule, financial, and technical objectives.
• Collaborate with structural/thermal analysts, materials engineering, quality, safety, supply chain, operations, and program leadership to develop and refine design solutions.
• Support factories and suppliers with product development, integration, troubleshooting, and obsolescence management, domestically and internationally.
• Conduct trade studies, participate in design peer reviews, and resolve technical action items.
• Apply thermal, structural, dynamic, and reliability analysis results to improve mechanical designs.
• Apply Geometric Dimensioning and Tolerancing (GD&T) principles, including performing and reviewing tolerance analyses to ensure proper form, fit, and function.
• Improve designs using DFMA and producibility principles.
• Develop and maintain the technical data package (TDP), ensuring capabilities and requirements compliance.
• Serve as responsible engineer or subsystem lead, directing and reviewing work from team members with limited supervision.
• Utilize Raytheon hardware tools, processes, and standards across all phases of development.
• Support First Article Inspection (FAI) and Raytheon Source Inspection (RSI) in partnership with Quality Engineering.
• Contribute to one or more of our contract-funded and internal research projects at varying stages of proposal, design, and integration/test.

Qualifications You Must Have:

• Typically requires a degree in Science, Technology, Engineering or Mathematics (STEM) and a minimum of 10 years of prior relevant experience or An Advanced Degree in a related field and minimum 7 years experience
• Experience in a technical leadership role with exposure to the full development lifecycle.
• Experience with aluminum casting and machining processes.
• Ability and willingness to travel domestically to casting and machining suppliers up to 75%.
• Experience leading and conducting trade studies; developing designs and requirements; and supporting integration and test of mechanical products.
• Experience with First Article Inspection (FAI).
• Experience with ANSI/ASME Y14.5 GD&T and tolerance analysis.
• Proficiency in CREO (Pro/E) or similar 3D CAD solid-modeling tools.
• Experience working with suppliers that deliver mechanical products, machined parts, and electronics.
• Experience supporting development and production programs for military applications.
• Ability to review and interpret technical documentation in a production environment.
• Experience supporting full-rate production of missile components and assemblies.
• Experience creating mechanical drawings or engineering documentation.
• Proven ability to work across multiple functional and disciplinary organizations to resolve technical challenges.
• Ability to work autonomously with minimal supervision.

Qualifications We Prefer:

• Strong communication skills with the ability to present complex technical concepts clearly.
• Experience preparing technical proposals and delivering technical presentations.
• Engineering experience across the full missile product lifecycle.
• Knowledge of Technical Data Package development and compliance.
• Experience supporting manufacturing and supplier engagements.
• Familiarity with USG, DCMA, or customer involvement during development and sell-off activities.
• Demonstrated collaboration, problem-solving ability, and a process-improvement mindset.

What We Offer

Our values drive our actions, behaviors, and performance with a vision for a safer, more connected world. At RTX we value: Safety, Trust, Respect, Accountability, Collaboration, and Innovation.

The salary range for this role is 132,400 USD - 251,600 USD. The salary range provided is a good faith estimate representative of all experience levels. RTX considers several factors when extending an offer, including but not limited to, the role, function and associated responsibilities, a candidate’s work experience, location, education/training, and key skills. Hired applicants may be eligible for benefits, including but not limited to, medical, dental, vision, life insurance, short-term disability, long-term disability, 401(k) match, flexible spending accounts, flexible work schedules, employee assistance program, Employee Scholar Program, parental leave, paid time off, and holidays. Specific benefits are dependent upon the specific business unit as well as whether or not the position is covered by a collective-bargaining agreement. Hired applicants may be eligible for annual short-term and/or long-term incentive compensation programs depending on the level of the position and whether or not it is covered by a collective-bargaining agreement. Payments under these annual programs are not guaranteed and are dependent upon a variety of factors including, but not limited to, individual performance, business unit performance, and/or the company’s performance. This role is a U.S.-based role. If the successful candidate resides in a U.S. territory, the appropriate pay structure and benefits will apply. RTX anticipates the application window closing approximately 40 days from the date the notice was posted. However, factors such as candidate flow and business necessity may require RTX to shorten or extend the application window.

RTX is an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, age, disability or veteran status, or any other applicable state or federal protected class. RTX provides affirmative action in employment for qualified Individuals with a Disability and Protected Veterans in compliance with Section 503 of the Rehabilitation Act and the Vietnam Era Veterans' Readjustment Assistance Act.

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