Senior Mechanical Engineer, Production / Sustainment

BAE Systems•Nashua, NH

2d•$89,650 - $152,460•Onsite

About The Position

BAE Systems is seeking a Senior Mechanical Engineer to join its Countermeasure & Electromagnetic Attack Solutions team in Nashua, New Hampshire. The team develops next-generation threat detection and countermeasure solutions that support electronic warfare and mission survivability. This role spans the product lifecycle, including business capture, development, production, testing, and sustainment, for complex defense products and technologies. It involves close collaboration with electrical, mechanical, software, firmware, and test engineers, as well as product managers and other stakeholders. The position is full-time and performed onsite due to the need for consistent in-person collaboration and the nature of the work. The engineer will help ensure the performance, quality, and reliability of electronic products through design, analysis, prototyping, and testing. The role emphasizes Agile hardware development, risk-reduction prototyping, and requirements-driven design and verification. The ideal candidate is detail-oriented, analytical, committed to continuous improvement, and interested in continued technical and leadership growth.

Requirements

Bachelor's degree in Mechanical Engineering.
At least 4 years of experience designing, testing, and troubleshooting high-reliability embedded systems, or at least 2 years with an MS in Mechanical Engineering.
Demonstrated understanding of mechanical principles and test methodologies, and ability to work with advanced test equipment and cutting-edge technology.
Strong hands-on laboratory experience with instrumentation, equipment, and processes.
Active DOD security clearance.

Nice To Haves

Understanding of heat transfer principles, strength of materials, materials selection, and design for vibration environments, with the ability to apply them to unique mechanical design challenges.
Experience with mechanical engineering design and analysis tools, including ANSYS Workbench/Mechanical, PTC Creo, MATLAB/Simulink, Siemens NX, and ANSYS Icepak.
Familiarity with design, analysis, and manufacturing standards for complex multilayer rigid and rigid-flex CCAs.
Knowledge of engineering development processes for the aerospace and defense industry, including designing and testing to ASTM, SAE, DO, and MIL-STD-810.
Agile hardware development experience and a self-starter approach.
Exceptional ingenuity, creativity, and resourcefulness.
Control account management experience.
Experience with LRIP/FRP, especially electronics manufacturing and test methodologies.
Familiarity with AS9145-compliant processes.
Strong written and verbal communication skills.

Responsibilities

Lead mechanical engineering design, development, integration, testing, and production of complex military systems.
Generate 3D solid models, drawings, and documentation using GD&T principles.
Perform tolerance analyses to assure fit and function.
Perform thermal, structural/stress, and modal/vibration analyses.
Assess designs against environmental requirements.
Develop prototypes and conduct test and verification efforts.
Partner with other engineering disciplines and operations personnel to develop solutions that adhere to DTUPC, DFT, and DFM requirements.
Support resolution of technical issues discovered during manufacture and testing of deliverable hardware.
Evaluate and troubleshoot mechanical faults and issues; assess test failures for root cause and identify disposition and corrective actions.
Design test equipment to ensure the performance and integrity of manufactured products.
Participate in requirements development, perform technical trade studies, and evaluate technology insertion and upgrades.
Develop and execute test plans, including integration of test solutions, and provide detailed reports on test results.
Participate in new business capture.