Senior Mechanical Engineer

The role

This person will design, develop, package, integrate, and qualify ruggedized sensor systems, avionics, and electronic hardware. The role spans the product lifecycle from concept through production and sustainment for aerospace and defense applications.

What you will do

• Design ruggedized electronic hardware, sensor systems, avionics, enclosures, structures, mechanisms, and support equipment
• Develop and maintain 3D CAD models, complex assemblies, detailed drawings, installation documentation, and interface control documents
• Own the design and documentation of assigned components, assemblies, and mechanical subsystems
• Track and manage size, weight, and mechanical allocations
• Perform structural and thermal analyses, hand calculations, requirements analysis, and design verification
• Support prototype fabrication, assembly, mechanical integration, testing, qualification, fit-check, installation, alignment, and troubleshooting
• Collaborate with multi-disciplinary teams to resolve integration challenges
• Support make/buy evaluations, production transition, DFMA, configuration control, fielding, and sustainment
• Participate in design reviews and failure investigations

Required qualifications

• Bachelor’s degree in Mechanical Engineering or a related discipline
• 4+ years of relevant experience in mechanical design and integration of electronic hardware for aerospace, defense, or similar applications
• Strong proficiency with mechanical CAD tools, such as SolidWorks or equivalent
• Experience producing and reviewing production-ready mechanical drawings and documentation
• Understanding of mechanical interfaces, tolerancing, alignment, installation practices, GD&T, tolerance analysis, and configuration-controlled documentation
• Experience designing or integrating mechanical hardware for RF, avionics, power electronics, embedded computing, or similar products
• Familiarity with structural analysis methods, including hand calculations and FEA
• Experience supporting prototype builds, integration, testing, or qualification activities
• Familiarity with ruggedized hardware and applicable environmental requirements
• Strong problem-solving skills, attention to detail, and ability to work in fast-paced, multi-disciplinary development environments
• Ability to obtain and maintain a U.S. security clearance

Nice to have

• Master’s degree in Mechanical Engineering or a related field
• Experience supporting environmental qualification testing and analysis, including thermal cycling, vibration, and shock
• Experience with commercial FEA or multiphysics simulation tools, such as NASTRAN, ABAQUS, ANSYS, COMSOL, or similar tools
• Familiarity with military and aerospace standards, including MIL-STD-810
• Familiarity with military and aerospace connectors, such as MIL-DTL-38999, ARINC, and Micro-D
• Experience with mechanisms, actuation systems, structures, thermal management, packaging, cable routing, connector layouts, or electromechanical integration
• Experience with additive manufacturing, CNC machining, fabrication, assembly, and prototype development
• Hands-on experience working with machine shop and prototype lab equipment

Benefits

• Medical, dental, and vision benefits 100% paid for by the company
• 401k with 50% company match up to 6% of pay
• FSA
• HSA
• life insurance
• Free daily lunch
• No meeting Fridays
• unlimited PTO
• casual dress code
• pre-IPO stock option grants
• relocation assistance

Before you apply

• Ability to obtain and maintain a U.S. security clearance

About the company

CHAOS Industries is a defense company founded in 2022 that uses Coherent Distributed Networks (CDN™) to empower warfighters and commercial operators. The company is headquartered in Los Angeles with global offices.