Senior Mechanical Engineer

Role Overview:

CHAOS is seeking a Senior Mechanical Engineer to support the hands-on design, development, packaging, integration, and qualification of ruggedized sensor systems, avionics, electronic hardware, and related mission-critical systems for dual-use aerospace and defense applications. The ideal candidate brings strong mechanical design and CAD expertise, experience with complex assemblies and integrated systems, and demonstrated prototyping, analysis, and problem-solving skills.

The position spans the product lifecycle from concept development and architecture through detailed design, analysis, prototyping, qualification testing, production, fielding, and sustainment. Design challenges may include structures, enclosures, mechanisms, electromechanical hardware, thermal solutions, support equipment, and other systems deployed across land-, sea-, and air-based platforms.

Responsibilities:

• Design ruggedized electronic hardware, sensor systems, avionics, enclosures, structures, mechanisms, and related support equipment in accordance with program requirements and applicable standards
• Develop and maintain 3D CAD models, complex assemblies, detailed drawings, installation documentation, and interface control documents (ICDs)
• Own the design and documentation of assigned components, assemblies, and mechanical subsystems
• Track and manage size, weight, and mechanical allocations for electronic assemblies and integrated hardware
• Perform first-order structural and thermal analyses, hand calculations, requirements analysis, and design verification activities
• Support prototype fabrication, assembly, mechanical integration, testing, qualification, fit-check, installation, alignment, and troubleshooting activities
• Collaborate with mechanical, electrical, RF, power, manufacturing, systems engineering, customers, suppliers, and platform providers to resolve integration challenges
• Support make/buy evaluations, production transition, Design for Manufacturing and Assembly (DFMA), configuration control, fielding, and sustainment activities
• Participate in design reviews, failure investigations, and other technical decision-making activities

Minimum Requirements:

• 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, including complex parts and assemblies
• 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 effectively in fast-paced, multi-disciplinary development environments
• Ability to obtain and maintain a U.S. security clearance

Preferred Requirements:

• 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

Why CHAOS?

• Health Benefits: Medical, dental, and vision benefits 100% paid for by the company
• Additional benefits: 401k (+ 50% company match up to 6% of pay), FSA, HSA, life insurance, and more
• Our Perks: Free daily lunch, ‘No meeting Fridays’, unlimited PTO, casual dress code
• Compensation Components: Competitive base salaries, generous pre-IPO stock option grants, relocation assistance, and (coming soon!) annual bonuses
• Team Growth: 250 employees and counting across 5 global offices

The stated compensation range reflects only the targeted base compensation range and excludes additional earnings such as bonus, equity, and benefits. If your compensation requirements fall outside of the range, we still encourage you to apply. The salary range for this role is an estimate based on a range of compensation factors, inclusive of base salary only. Actual salary offer may vary based on (but not limited to) work experience, education and/or training, critical skills, and/or business considerations.