Principal Mechanical (Design) Engineer

Elbit America • Roanoke, VA

23h

About The Position

Leads the mechanical design of electro‑optical (EO) systems and opto‑mechanical assemblies from concept through production. Designs major components or major portions of a functional system to develop or improve products and facilitate manufacturing operations. Translates customer and market requirements into robust mechanical architectures, balancing performance, manufacturability, cost targets, and configuration control. Utilizes CAD/PLM tools to create detailed models, drawings, and documentation; performs mechanical and thermal analyses; and works as a cross‑functional liaison to ensure seamless system integration and production readiness. Coaches and trains junior and senior engineers, establishes reusable design patterns and playbooks, and serves as final technical approver for critical designs.

Requirements

• BS in Mechanical Engineering (or related field) and 10+ years product/tool design experience with CAD tools (preferably Creo Parametric with Windchill); or MS in ME and 8+ years relevant experience.
• CAD/PLM: Expert-level parametric modeling per best practices (Creo preferred); Windchill PLM; surfacing and mechanism design experience a plus.
• Analysis: Proven depth in structural FEA (Ansys or Creo) and thermal analysis experience.
• Standards & methods: Advanced GD&T per ASME standards; complex tolerance analysis; DFM/DFA; DTUPC; able to teach and certify others on internal standards.
• Manufacturing knowledge: Machining, sheet metal, injection molding, adhesives/sealants, and additive manufacturing (3D printing a plus).
• Systems integration: Extensive experience with sensors, imaging modules, fiber‑optic, electro-mechanical or opto‑electronic subassemblies, and EMI/ESD practices.
• Cross‑functional collaboration: Demonstrated capability to mentor, train, and develop junior engineers; lead across PEMs, SEs, TPMs, Supply Chain, Vendors, and PMs; chair reviews and approve designs.
• Innovation and IP: identify opportunities for new mechanisms, materials, and processes; assist with disclosures and patent filings where appropriate.
• Tools: Proficiency with MS Office (Outlook, Word, Excel, PowerPoint).
• Clearance: Must be able to obtain a U.S. Secret Clearance.
• Training pre‑requisites (within one year of taking position): ESD; Safety Training as dictated by the Safety Department.
• Expert in Creo Parametric, tolerance analysis, GD&T, FEA (Ansys or Creo), and thermal modeling; able to teach methodologies and review others’ work effectively.
• Strong communication: can write standards, playbooks, and training materials; can present to executives and external customers.
• Influence and negotiation aligns stakeholders on complex trade‑offs and risk mitigation.
• Ability to work in lab and production areas, use PPE as required, and lift up to 25 lbs.

Responsibilities

• Own the mechanical architecture and design of electro‑optical enclosures, precision mounts, thermal frames, seals, and structural elements. Ensure optical alignment stability, thermal management, EMI/ESD robustness, and environmental durability.
• Create 3D CAD models, detailed drawings, and engineering documentation per internal standards (Creo Parametric preferred; Windchill PLM).
• Generate system‑level mechanical layouts and thoroughly detailed component designs with minimal supervision. Perform component‑level and assembly‑level tolerance analyses and stack‑ups to guarantee fit, function, and alignment.
• Analyze and optimize designs using structural (FEA) and thermal simulations (Ansys or Creo Simulation), material selection, finishes, and fabrication processes to meet performance and reliability goals. Translate CTQs into tolerance budgets and verify with analytical stack‑ups and build data.
• Design for manufacturing and cost: apply DFM/DFA and Design‑to‑Unit‑Production‑Cost (DTUPC) principles. Partner with manufacturing engineering to design or revise tooling, fixtures, and assembly methods.
• Document Critical‑to‑Quality (CTQ) characteristics for purchased parts and assemblies. Define drawing GD&T and datum strategies; Lead tolerance analysis, approve component‑level and assembly‑level stack‑ups, select worst‑case or statistical approaches, and correlate tolerance budgets to supplier capability and inspection plans
• Own supplier technical engagement: define capability targets (Cp/Cpk) for CTQs, review first articles, and resolve process gaps; escalate and lead corrective actions.
• Prepare for and lead/contribute to design reviews (internal and external), risk assessments (DFMEA/PFMEA), and reliability planning; participate in peer reviews of complex mechanical approaches. Present tolerance budgets, key stack‑ups, and inspection plans.
• Prototype, assemble, and debug early units; support fabrication, inspection, and iterative refinement; assist production during initial builds and resolve build issues rapidly. Measure critical dimensions and update drawings/processes to close gaps.
• Mentor and train: provide structured training for junior engineers and peers in CAD best practices, tolerance analysis, GD&T per ASME, thermal and structural analysis, DFM/DFA, and EO integration. Pair on critical designs and conduct regular coaching sessions.
• Integrate cross‑functionally with Project Engineering Managers (PEMs), Systems Engineers (SEs), Technical Product Managers (TPMs), Supply Chain, external Vendors, and Program Managers (PMs) to align requirements, schedules, budgets, and trade‑offs through NPI gates.
• Capture voice of the customer and apply Human Factors principles to improve usability, serviceability, and safety. Ensure compliance with applicable standards and company policies (e.g., GD&T per ASME, product safety, environmental test methods, configuration control).

Benefits

• Most locations offer a 9/80 schedule, providing every other Friday off
• Competitive compensation & 401(k) program to plan for your future
• Robust medical, dental, vision, & disability coverage with qualified wellness discounts
• Basic Life Insurance and Additional Life & AD&D Insurances are available
• Flexible Vacation & PTO
• Paid Parental Leave
• Generous Employee Referral Program
• Voluntary Benefits Available: Longer Term Care, Legal, Identity Theft, Pet Insurance, and more
• Voluntary Tricare Supplement available for military retirees

What This Job Offers

• Job Type: Full-time
• Career Level: Mid Level