Principal Mechanical Engineer

Attalon, Inc. • Warren Township, NJ

41d • $133,500 - $240,500 • Onsite

About The Position

This Principal Mechanical Engineer must be a highly experienced technical leader responsible for driving innovation and leading the development of advanced mechanical and optical systems, including laser systems, bulk optics, and fiber optic technologies, for aerospace and defense applications. This role oversees all phases of product development—from conceptual design and prototyping through manufacturing and deployment—while ensuring efficient systems integration and high-performance solutions. The position requires deep expertise in opto-mechanical and photonic systems, hands-on experience with fiber-optic technologies and laser systems, and a proven ability to lead cross-functional teams and mentor the next generation of engineers. A key focus is the delivery of cost-effective, cutting-edge solutions designed to operate in demanding environments such as terrestrial and space applications.

Requirements

• A Bachelor’s degree in mechanical engineering or a related field, with 10-12 years of relevant experience.
• Extensive experience in the design, development, and integration of advanced optical, fiber optic, and laser systems, including bulk optics, optical assemblies, and opto-mechanical components for industrial or military applications.
• Expertise in fiber optic technologies, including splicing, cleaving, tapering, recoating, and alignment. Proven ability to develop innovative manufacturing processes and systems for fiber handling, in-situ assembly, material curing, and high-precision optics applications.
• Proficient in conducting and guiding preliminary structural, thermal, and environmental analyses using FEA and related methods during the design process, with an emphasis on optimizing designs for manufacturability, cost-effectiveness, and system reliability.
• Extensive experience with CAD tools (SolidWorks is preferred), including high-fidelity part and assembly modeling, detailed drawing creation, tolerance analysis, and adherence to industry standards such as GD&T, ASME Y14.5, MIL specs, and ASTM standards.
• Strong track record of managing the full product lifecycle—from conceptual design and prototyping to manufacturing, qualification, and deployment—for opto-mechanical and photonic systems in industrial applications.
• Demonstrated ability to lead and collaborate with multidisciplinary teams, including optical, electrical, systems, and controls engineers, to deliver integrated solutions for complex engineering challenges.
• Experience driving innovation in laser systems, bulk optics, and photonic products while leveraging advanced technologies for applications in industrial R&D and precision manufacturing.
• Expertise in product assembly, integration, and testing processes, including the development of tooling, manufacturing processes, and detailed test plans. Skilled at conducting performance validation against stringent optical, mechanical, and environmental requirements.
• Recognized for providing hands-on mentoring and technical leadership to junior engineers and cross-functional teams, fostering a culture of collaboration, innovation, and professional growth.

Nice To Haves

• Master’s degree with 8-10 years experience, or Ph.D. with 7+ years experience).
• In-depth knowledge of Lean Manufacturing principles, DFMA techniques, and process optimization for high-precision manufacturing, enhancing efficiency and reducing costs.
• Expertise in sourcing, qualifying, and managing vendors, as well as overseeing cost control, ensuring quality assurance, and leading international technology transfer to enable scalable and cost-efficient manufacturing operations.
• Proven experience managing technical programs and projects, driving progress on strategic initiatives, aligning cross-functional teams, managing timelines and budgets, and ensuring successful product delivery.
• Broad understanding and application of photonics, laser systems, fiber optics technologies, and bulk optical systems in high-performance aerospace and defense related R&D environments.

Responsibilities

• Lead the design and development of advanced optical and mechanical systems: Oversee the engineering of large-scale mechanical systems and opto-mechanical subsystems, including bulk optics, laser systems and fiber optic assemblies. Support the design and development of optical support structures, thermal management, and alignment interfaces while packaging delicate optics for demanding military environments for both prototyping and production-level solutions.
• Perform and oversee preliminary analysis: Conduct and guide initial structural, thermal, and environmental analyses to validate mechanical and optical system designs. Provide insights to address application challenges, such as heat dissipation in solid-state laser systems, stress management in fiber optic assemblies and secure mounting that can withstand launch into space or operation on ground and airborne platforms. Participate in risk-reduction efforts through breadboards, prototypes, and subscale testing to refine and optimize designs.
• Drive innovations in the opto-mechanics of laser systems: Lead the development of innovative opto-mechanics for fiber, diode-pumped solid-state and semiconductor lasers. Deploy the latest thermal management, fiber processing, and optics-mounting techniques and materials to develop innovative solutions.
• Manage detailed engineering designs: Support systems engineering in the decomposition of system-level specifications into sub-system and component-level requirements. Develop, review, and release detailed CAD models, part and assembly drawings, and tolerance analyses to support manufacturable and reliable designs. Ensure compliance with GD&T, ASME Y14.5, and other industry design standards for laser systems, bulk optics, and fiber optic assemblies.
• Oversee full product lifecycle development: Direct product development activities from concept through production and deployment. Collaborate with optical, mechanical, electrical, and systems engineering teams, ensuring the seamless integration of fiber optics, laser systems, and precision mechanical elements. Lead efforts to meet rigorous environmental and performance requirements in industrial and high-reliability applications.
• Collaborate with vendors and manage supply chains: Assist the management of relationships with vendors, including sourcing, qualification, and quality oversight, to ensure the reliable delivery of components for fiber optic and photonic systems. Provide leadership in technology transfer projects, both domestic and international, to establish scalable manufacturing processes and optimize efficiency.
• Lead assembly, integration, and testing efforts: Oversee mechanical aspects of product assembly and integration processes, ensuring precise alignment of optical components, fiber handling systems, and laser systems with mechanical designs. Develop tooling, work instructions, and test plans for robust and efficient assembly and system validation. Oversee performance testing on opto-mechanical systems to meet optical, mechanical, and thermal requirements.
• Provide technical leadership and mentorship: Serve as a subject-matter expert on the mechanical aspects of laser and fiber optic systems, offering strategic guidance and technical direction to resolve complex engineering challenges. Actively mentor junior engineers and cross-functional team members, fostering technical growth, collaboration, and innovation across the organization.

What This Job Offers

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