Staff Mechanical Engineer

The role

The Staff Mechanical Engineer will perform hands-on design, development, packaging, integration, and qualification of ruggedized sensor systems, avionics, and electronic hardware. This role supports the product lifecycle from concept through sustainment for dual-use aerospace and defense applications.

What you will do

• Perform hands-on mechanical design and integration of ruggedized electronic hardware, sensor systems, avionics, structures, mechanisms, enclosures, and related support equipment
• Own the mechanical design and integration of defined subsystems, product areas, or major assemblies
• Perform trade studies and recommend path forward
• Develop and maintain 3D CAD models, assemblies, detailed drawings, installation documentation, and interface control documents (ICDs)
• Develop mechanical designs subject to structural, thermal, environmental, manufacturability, installation, and operational requirements
• Perform first-order structural and thermal analyses, hand calculations, requirements analysis, and design verification activities
• Lead design review on owned design
• Work collaboratively with multi-disciplinary teams to resolve integration challenges
• Support system integration, qualification, fit-check, installation, alignment, troubleshooting, prototype fabrication, assembly, and transition to production
• Support configuration control, make/buy evaluations, fielding, and sustainment of deployed systems

Required qualifications

• Bachelor’s degree in Mechanical Engineering or a related discipline
• 7+ years of progressively responsible 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, including complex assemblies and detailed design
• Experience producing and reviewing production-ready mechanical drawings and documentation
• Understanding of mechanical interfaces, tolerancing, alignment, installation practices, and interface control documents (ICDs)
• Familiarity with military and aerospace connectors, such as MIL-DTL-38999, ARINC, and Micro-D
• Understanding of mechanical drafting standards, GD&T, tolerance analysis, and configuration-controlled documentation
• Familiarity with structural analysis methods, including hand calculations and FEA
• Experience designing or integrating ruggedized hardware and considering applicable environmental requirements
• Experience interpreting and applying applicable military and aerospace standards, including MIL-STD-810 where relevant
• Strong written and verbal communication skills and ability to operate effectively in 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 mechanisms, actuation systems, structures, thermal management, packaging, cable routing, connector layouts, or electromechanical integration
• Experience with commercial FEA or multiphysics simulation tools, such as NASTRAN, ABAQUS, ANSYS, COMSOL, or similar tools
• Experience with prototyping, additive manufacturing, CNC machining, fabrication, assembly, and production transition
• Familiarity with aerospace, defense, military, or other ruggedized hardware standards and specifications

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
• annual bonuses (coming soon)

Before you apply

• Ability to obtain and maintain a U.S. security clearance
• CHAOS Industries does not accept unsolicited resumes or outreach

About the company

CHAOS Industries was founded in 2022 and has raised a total of $1 billion in funding. The company is headquartered in Los Angeles and focuses on modern defense with a multi-product portfolio.