Mechanical Engineer III

TSC•Huntsville, AL

About The Position

Falcata is seeking an experienced individual contributor to support its Products Engineering Solutions (PES) team in Huntsville, Alabama. The Mechanical Engineer III will own mechanical and electromechanical designs for RF technology prototypes from concept through fabrication, integration, and test. The role involves working across disciplines, making practical design trade-offs as schedules change, and providing technical guidance to less-experienced engineers. The engineer will design housings, enclosures, brackets, adapters, and assemblies; create 3D CAD models and production-ready drawings; define mechanical concepts; maintain bills of materials; and coordinate prototype procurement. The role applies materials selection, tolerance analysis, design for manufacturability, and design for assembly to meet performance and build requirements. The position partners with electrical and RF engineers to resolve packaging, size, weight, thermal, and interface constraints for antennas and electronics in host platforms. It leads mechanical integration, supports prototype assembly and testing, resolves fabrication and build issues with manufacturers and vendors, leads design reviews, and maintains accurate design records and change documentation. The engineer also prepares technical reports and presentations, communicates project status and risks, and mentors less-experienced engineers.

Requirements

Bachelor’s degree in mechanical engineering or equivalent.
5–7 years of experience developing mechanical or electromechanical products.
Advanced proficiency with SolidWorks or equivalent 3D CAD software for complex part and assembly modeling and engineering drawing creation.
Demonstrated ability to own mechanical designs from concept through prototype build and test, with sound judgment in materials, manufacturing, and tolerance decisions.
Ability to create and review technical drawings, BOMs, design documentation, and mechanical interfaces for fabrication and integration.
Strong written and verbal communication skills.
Experience coordinating work across engineering disciplines and external fabrication partners.

Nice To Haves

Experience using structural finite element analysis (FEA) or computational fluid dynamics (CFD) tools to inform design decisions, including SolidWorks Simulation.
Working knowledge of geometric dimensioning and tolerancing (GD&T) under ASME Y14.5.
Hands-on experience integrating and troubleshooting electromechanical prototypes, electronics, RF hardware, or antennas.
Experience applying DFM and DFA principles and resolving design issues with manufacturing partners.
Experience with machining, sheet metal fabrication, 3D printing, injection molding, casting, and collaboration with vendors or machine shops.
Experience planning design verification, interpreting test results, and documenting design changes and technical trade-offs.

Responsibilities

Own mechanical designs for housings, enclosures, brackets, adapters, and assemblies, including 3D CAD models and production-ready engineering drawings.
Define mechanical concepts and trade-offs, maintain bills of materials (BOMs), and coordinate procurement of prototype parts and assemblies.
Apply materials selection, tolerance analysis, design for manufacturability (DFM), and design for assembly (DFA).
Partner with electrical and RF engineers to address packaging, size, weight, thermal, and interface constraints for antennas and electronics in host platforms.
Lead mechanical integration of Falcata electronics into host platforms, including fit checks, design changes, and hands-on prototype support.
Communicate technical requirements to manufacturers and vendors, review fabrication feedback, and resolve build issues.
Plan and support prototype assembly, mechanical testing, and troubleshooting, and use results to improve designs.
Lead mechanical design reviews, explain design decisions and risks, and incorporate feedback from engineering and manufacturing stakeholders.
Maintain accurate and complete drawings, BOMs, design records, and change documentation in accordance with company standards.
Prepare technical reports and presentations, communicate status and risks, and mentor less-experienced engineers on design and documentation practices.