Company Description

Must be eligible to obtain a U.S. security clearance

We're seeking a Hardware Engineer to lead the mechanical and thermal design of rugged, high-performance defense platforms. You'll work on structural simulation, thermal management, and rapid prototyping-taking systems from concept to field validation. This is a highly hands-on role that involves testing, iteration, and close collaboration with cross-functional teams.

Job Description

Thermal & Structural Engineering

• Design and validate active and passive thermal management systems for high-power laser components

• Conduct FEA for stress, vibration, modal analysis, and thermal performance using tools like ANSYS or SolidWorks Simulation

• Optimize designs for durability, weight, and thermal reliability under dynamic load conditions

Mechanical Design & Prototyping

• Create 3D CAD models for structural and thermal hardware using SolidWorks, Creo, or equivalent

• Rapidly build and iterate mechanical prototypes using CNC, additive manufacturing, or other methods

• Plan and conduct environmental tests: vibration, shock, and field robustness trials

Material Selection & DFM

• Select and qualify metals, polymers, and composites based on thermal, mechanical, and EMI requirements

• Run DFM reviews to optimize geometry, tolerances, and manufacturability

• Collaborate with suppliers and manufacturers to transition prototypes to production

Manufacturing & Documentation

• Generate GD&T drawings, BOMs, and assembly instructions

• Ensure compliance with MIL-STD and ITAR standards throughout hardware lifecycle

• Support final assembly, system integration, and field testing

Cross-Functional Integration

• Partner with optics, firmware, electronics, and control systems teams to integrate your designs into full systems

• Provide hands-on support during product builds and test cycles

Qualifications

• 2-8 years in mechanical or hardware engineering (defense, aerospace, robotics, or similar)

• Proficient in CAD tools (SolidWorks, Creo, etc.)

• Strong in FEA tools for thermal and structural analysis (ANSYS, SolidWorks Simulation)

• Experience with CFD, heat transfer simulation, and vibration/shock testing

• Hands-on with prototyping and fixture development

• Familiarity with material properties, design tolerances, and manufacturing methods

• BS or MS in Mechanical Engineering, Aerospace Engineering, or related field

• Strong problem-solving skills, fast execution, and excellent communication in cross-functional environments

• Experience with vacuum or environmental chamber testing

• Familiarity with optical alignment or laser safety standards

• Background in EMI/EMC shielding and design

• Experience with ITAR compliance or active security clearance