Senior Mechanical Engineer

CHAOS Industries•El Segundo, CA

11d•$140,000 - $176,000•Onsite

About The Position

CHAOS is seeking a Senior Mechanical Engineer to support the hands-on design, development, packaging, integration, and qualification of ruggedized sensor systems, avionics, electronic hardware, and related mission-critical systems for dual-use aerospace and defense applications. The ideal candidate brings strong mechanical design and CAD expertise, experience with complex assemblies and integrated systems, and demonstrated prototyping, analysis, and problem-solving skills. The position spans the product lifecycle from concept development and architecture through detailed design, analysis, prototyping, qualification testing, production, fielding, and sustainment. Design challenges may include structures, enclosures, mechanisms, electromechanical hardware, thermal solutions, support equipment, and other systems deployed across land-, sea-, and air-based platforms.

Requirements

Bachelor’s degree in Mechanical Engineering or a related discipline
4+ years of relevant experience in mechanical design and integration of electronic hardware for aerospace, defense, or similar applications
Strong proficiency with mechanical CAD tools, such as SolidWorks or equivalent, including complex parts and assemblies
Experience producing and reviewing production-ready mechanical drawings and documentation
Understanding of mechanical interfaces, tolerancing, alignment, installation practices, GD&T, tolerance analysis, and configuration-controlled documentation
Experience designing or integrating mechanical hardware for RF, avionics, power electronics, embedded computing, or similar products
Familiarity with structural analysis methods, including hand calculations and FEA
Experience supporting prototype builds, integration, testing, or qualification activities
Familiarity with ruggedized hardware and applicable environmental requirements
Strong problem-solving skills, attention to detail, and ability to work effectively in fast-paced, multi-disciplinary development environments
Ability to obtain and maintain a U.S. security clearance

Nice To Haves

Master’s degree in Mechanical Engineering or a related field
Experience supporting environmental qualification testing and analysis, including thermal cycling, vibration, and shock
Experience with commercial FEA or multiphysics simulation tools, such as NASTRAN, ABAQUS, ANSYS, COMSOL, or similar tools
Familiarity with military and aerospace standards, including MIL-STD-810
Familiarity with military and aerospace connectors, such as MIL-DTL-38999, ARINC, and Micro-D
Experience with mechanisms, actuation systems, structures, thermal management, packaging, cable routing, connector layouts, or electromechanical integration
Experience with additive manufacturing, CNC machining, fabrication, assembly, and prototype development
Hands-on experience working with machine shop and prototype lab equipment

Responsibilities

Design ruggedized electronic hardware, sensor systems, avionics, enclosures, structures, mechanisms, and related support equipment in accordance with program requirements and applicable standards
Develop and maintain 3D CAD models, complex assemblies, detailed drawings, installation documentation, and interface control documents (ICDs)
Own the design and documentation of assigned components, assemblies, and mechanical subsystems
Track and manage size, weight, and mechanical allocations for electronic assemblies and integrated hardware
Perform first-order structural and thermal analyses, hand calculations, requirements analysis, and design verification activities
Support prototype fabrication, assembly, mechanical integration, testing, qualification, fit-check, installation, alignment, and troubleshooting activities
Collaborate with mechanical, electrical, RF, power, manufacturing, systems engineering, customers, suppliers, and platform providers to resolve integration challenges
Support make/buy evaluations, production transition, Design for Manufacturing and Assembly (DFMA), configuration control, fielding, and sustainment activities
Participate in design reviews, failure investigations, and other technical decision-making activities