Staff Engineer - Mechanical

Thales; Irvine (CA); On-site; USD 125,000 - 223,000; Full time

Job summary

Thales is seeking a Staff Engineer - Mechanical in Irvine, CA, to lead design, development and lifecycle support of IFEC LRU products for aerospace programs. You will own mechanical architecture, guide cross-functional teams, and ensure compliance with DO-160 environmental and industry standards while optimizing performance, reliability, and manufacturability.

You will mentor engineers, drive design reviews, and partner with Systems, Electrical, Software, Manufacturing, Quality, and Supply Chain

Qualifications

• Bachelor’s degree in Mechanical Engineering; Master’s degree preferred.
• 15+ years of mechanical design experience in aerospace.
• Experience leading multi-program engineering teams.

Responsibilities

• Serve as the technical lead for design, development, integration, qualification, and lifecycle support of complex electro‑mechanical aerospace systems.
• Lead mechanical efforts addressing thermal management, structural integrity, vibration, EMI/ESD, reliability, manufacturability, and performance.
• Provide technical leadership across development programs, conduct trade studies, and influence architecture.
• Collaborate with Systems, Electrical, Software, Manufacturing, Quality, Supply Chain, and Program Management.
• Represent the organization in technical reviews, discussions, and presentations with customers and partners.
• Mentor engineers and promote engineering excellence and best practices.

Skills

Technical leadership

Cross-functional collaboration

Aerospace experience

Education

Bachelor's degree in Mechanical Engineering

Master's degree preferred

Job description

Location: Irvine, United States of America

Thales people architect solutions that enable two-thirds of planes to take off and land safely. We create in-flight entertainment systems that engross 50 million fliers every year and we develop the avionics that control the world’s largest commercial aircrafts. Our simulators train the next generation of pilots for fighter jets, transporters and search and rescue helicopters. And, together, each and every member of our aerospace team makes a difference.

Staff Mechanical Engineer

Irvine, CA (Fully Onsite)

Position Summary

Thales is looking for a Staff Engineer - Mechanical who will serve as a technical leader in the design, development, qualification, and lifecycle support of In-Flight Entertainment and Connectivity (IFEC) Line Replaceable Unit (LRU) products. This role is responsible for leading complex mechanical engineering initiatives, developing innovative design solutions, ensuring compliance with aerospace standards and regulatory requirements, and driving product performance, reliability, manufacturability, and cost objectives across multiple programs.

In this position, you will provide technical leadership across cross-functional engineering teams, influence mechanical architecture and design strategy, evaluate emerging technologies, resolve complex engineering challenges, and support products throughout their entire lifecycle. You will collaborate closely with Systems, Electrical, Software, Manufacturing, Quality, Supply Chain, and Program Management teams while mentoring engineers, promoting engineering best practices, and helping deliver high-quality aerospace products that meet customer requirements and business objectives.

Key Areas of Responsibility

• Serve as the technical lead for the design, development, integration, qualification, and lifecycle support of complex electro‑mechanical aerospace systems, ensuring compliance with customer requirements, certification standards, and business objectives.
• Lead complex mechanical engineering efforts by resolving technical challenges related to thermal management, structural integrity, vibration, EMI/ESD, reliability, manufacturability, and product performance.
• Provide technical leadership across multiple development programs by conducting trade studies, evaluating design alternatives, mitigating technical risks, and influencing product architecture and long‑term technology strategies.
• Collaborate with cross-functional teams including Systems, Electrical, Software, Manufacturing, Quality, Supply Chain, and Program Management to deliver high‑quality, cost‑effective mechanical solutions.
• Represent the organization as the primary mechanical engineering expert with customers, suppliers, certification authorities, and development partners by leading technical reviews, design discussions, and engineering presentations.
• Mentor and develop engineers while driving engineering excellence through design reviews, continuous improvement initiatives, adoption of emerging technologies, and the establishment of mechanical engineering best practices.

Minimum Qualifications

• Bachelor’s degree in Mechanical Engineering, Materials Engineering, or a related engineering discipline; Master’s degree preferred. Minimum of 15 years of mechanical design engineering experience within the aerospace industry.
• Proven experience serving as a technical lead, system architect, or recognized subject matter expert across multiple product development programs.
• Experience supporting Boeing, Airbus, or other major commercial aircraft OEM line‑fit programs, including DO-160 environmental qualification and aerospace certification activities.
• Demonstrated expertise leading innovation initiatives, advanced technology research, or intellectual property development for next‑generation aerospace products.
• Proven ability to provide technical leadership across geographically distributed engineering teams while mentoring engineers, influencing cross‑functional stakeholders, and advancing engineering best practices.

Preferred Qualifications

• Master’s degree in Mechanical Engineering or a related engineering discipline.
• Experience serving as the mechanical engineering technical authority across multiple product lines or geographically distributed engineering organizations.
• Demonstrated success leading innovation initiatives, advanced technology research, or intellectual property (patent) development.
• Experience establishing mechanical design standards, engineering best practices, and long‑term technology roadmaps.
• Proven ability to mentor, coach, and develop engineers while fostering technical excellence and continuous improvement across engineering teams.
• Experience representing the organization as a senior technical advisor with customers, suppliers, certification authorities, or industry partners during design reviews, technical discussions, and strategic engineering initiatives.

Special Position Requirements

• Travel: 10%

Applicants must be legally authorized to work in the United States for any employer at the time of hire. This position is not eligible for visa sponsorship or for assuming sponsorship of an employment visa now or in the future.

Thales champions inclusion and we believe diversity strengthens the fabric of our culture. Thales is an Equal Opportunity Employer, including disability/veterans.

The reference Total Target Compensation (TTC) market range for this position, inclusive of annual base salary and the variable compensation target, is between

Total Target Cash (TTC) 125,251.50 - 222,520.00 USD Annual

This reflects how companies in a similar industry and geographic region generally pay for similar jobs. This range helps the Company make pay decisions as one data point among many. Where a position falls within this range is also dependent on other factors including – but not limited to – the employee’s career path history, competencies, skills and performance, as well as the company’s annual salary budget, the customer’s program requirements, and the company’s internal equity. Thales may offer additional benefits and other compensation, depending on circumstances not related to an applicant’s status protected by local, state, or federal law.

(For Internal candidate, if you need more information, please raise HR request through MyThales)

Thales provides an extensive benefits program for all full‑time employees working 30 or more hours per week and their eligible dependents, including the following:

• Elective Health, Dental, Vision, FSA/HSA, Voluntary Life and AD&D, Whole Group Life w/LTC, Critical Illness, Hospital Indemnity, Accident Insurance, Legal Plan, Identity Theft, and Pet Insurance
• Retirement Savings Plan after 30 days of employment with a company contribution and a match, and with no vesting period
• Company paid holidays and Paid Time Off
• Company provided Life Insurance, AD&D, Disability, Employee Assistance Plan, and Well‑being Program