Mechanical Engineer – Product Design & Development

We are seeking a highly capable Mechanical Engineer specializing in Product Development and Mechanical Design to be deeply involved in the full product lifecycle—from concept generation to detailed design, analysis, prototyping, and transition to production.

This engineer will support and lead all mechanical aspects of ruggedized aerospace and military products, including structures, enclosures, thermal solutions, mechanisms, interface hardware, and electronics packaging. The role includes creating and maintaining drawing templates, documentation, and manufacturing ready outputs.

The ideal candidate is an analytical thinker and hands on designer who thrives in a fast paced R&D environment—tackling complex design challenges, innovating mechanical solutions, and performing structural and thermal analyses while leveraging practical engineering skills along with advanced simulation, modeling, and problem solving capabilities to produce robust, high quality products for mission critical applications.

Key Responsibilities:
• Lead mechanical product development and design across all phases, from concept to production release
• Design and model mechanical assemblies including enclosures, structural parts, mechanisms, brackets, mounting hardware, and electronics packaging
• Perform stack up analysis, GD&T application, tolerance analysis, and detailed dimensioning to ensure reliable fit and manufacturability
• Conduct or support structural, shock, vibration, modal, and thermal analyses for compliance with MIL STD 810 and related standards
• Create complete mechanical documentation packages including drawings, drawing templates, BOMs, and configuration controlled artifacts under AS9100 processes
• Apply Design for Manufacturability (DFM) and Design for Assembly (DFA) principles to support efficient, quality focused production
• Collaborate closely with a cross function engineering teams throughout the development
• Develop and implement thermal management strategies including conduction paths, heat sinking, interface materials, and airflow considerations
• Support ruggedization efforts: sealing, gasketing, coatings, shock and vibration protection, environmental hardening
• Assist in prototype development, machining, and vendor engagement
• Participate in design reviews, verification testing, and root cause analysis • Ensure final mechanical designs meet system level requirements, environmental constraints, manufacturability goals, and reliability expectations

Required Qualifications:
• BS in Mechanical Engineering
• Proficiency in SolidWorks or equivalent advanced 3D CAD tools
• Experience using FEA simulation tools such as Ansys Mechanical, SolidWorks Simulation, or equivalent for structural or thermal analysis
• Experience designing mechanical assemblies for electronics, electromechanical systems, or rugged hardware
• Strong understanding of structural mechanics, thermal fundamentals, stack up analysis, GD&T, and tolerance analysis
• Familiarity with aerospace/military mechanical design requirements and environmental qualification methodologies
• Experience using mechanical lab tools (calipers, force gauges, thermal sensors, etc.) for hands on verification
• Candidate must be a U.S. Citizen and possess the ability to obtain and maintain a security clearance.

Preferred Qualifications:
• MS in Mechanical Engineering with emphasis on structural or thermal design
• Experience designing ruggedized assemblies and thermal pathways for mission critical systems
• Aerospace, defense, or high reliability product development experience
• Working knowledge of machining processes, sheet metal design, injection molding, and additive manufacturing
• Familiarity with AS9100 quality systems, configuration management, and structured documentation workflows
• Understanding of EMI/EMC mechanical considerations such as shielding, gasketing, enclosure grounding, and conductive coatings
• Experience developing or maintaining engineering drawing templates, documentation standards, and mechanical design guidelines

Desired Attributes:
• Strong analytical and problem solving skills
• High attention to detail and commitment to quality
• Clear communication and technical writing ability
• Ability to work both independently and within multidisciplinary teams
• Passion for innovation and mission oriented engineering

Multiple locations: This role can be based at our CFD Research office in Dayton, OH (PREFERRED location), or our office in Huntsville, AL and Hollywood, AL will also be considered. This role is 100% onsite.