Senior Opto-Mechanical Engineer

CACI • Florham Park, NJ

4d • Onsite

About The Position

CACI is looking for a Senior Opto-Mechanical Engineer to join our Photonics team. This role involves designing the packaging for complex subsystems with optical, photonic, optoelectronic, electrical, and mechanical elements for R&D and production programs for U.S. government customers. The engineer will own mechanical designs from concept through flight qualification, including requirements definition, trade studies, and detailed design. Responsibilities include collaborating with optical engineers, designing optical mounts and systems for challenging environments, developing and maintaining optical alignment strategies, producing build-to drawings, and managing third-party vendors. The role also supports integration, alignment, and test activities, and may involve leading a team or supervising lab technicians.

Requirements

• BS in Mechanical Engineering and a minimum of 7 years of related experience or equivalent combination of education, skills, and experience.
• Proficient use of computer-aided design and analysis software, with SolidWorks and Ansys strongly preferred.
• Experience working with optomechanical systems, precision structures, or high-stability mechanical assemblies.
• Strong understanding of optical mounts, materials, tolerancing, and alignment techniques.
• Familiarity with use of and preparation of CAD models for use in FEA software for thermal and structural (shock and vibration) analysis.
• Familiarity with Design for Manufacturing (DFM) and Design Failure Mode and Effects Analysis (DFMEA) methodologies, with experience applying these principles to improve product quality and manufacturability.
• Must be a US Citizen.

Nice To Haves

• Experience in the design of complex subsystems with optical, photonic, optoelectronic, electrical, and mechanical elements.
• Experience with gimbal systems or other precision motion control mechanisms, including design, integration, and optimization for applications in optical systems or robotics.
• Familiarity with material behavior in space environments, such as CTE matching, thermal gradients, and outgassing considerations.
• Proven experience conducting mechanical simulations using ANSYS Mechanical (static, modal, thermal, nonlinear, or dynamic).
• Experience in optical and electronic subassembly layout including board physical design, chassis or enclosure design, optical fiber routing, and electrical and optical connector selection.
• Master’s degree preferred.

Responsibilities

• Design the packaging for complex subsystems with optical, photonic, optoelectronic, electrical, and mechanical elements for R&D and production programs for U.S. government customers.
• Own mechanical designs from concept through flight qualification, including requirements definition, trade studies, and detailed design.
• Collaborate with optical engineers to translate optical prescriptions into robust mechanical designs.
• Design optical mounts and systems for launch loads, vibration, shock, thermal cycling, and vacuum environments.
• Develop and maintain optical alignment strategies, including athermalization and stability over temperature.
• Produce build-to drawings and data packages.
• Collaborate with and manage 3rd party vendors to resolve specification, performance, and reliability issues and realize the commercial and custom-machined parts necessary to build the subsystem.
• Support integration, alignment, and test (I&T) activities, including environmental testing and troubleshooting.
• May lead a team of other designers, analysts, and engineering professionals.
• May directly supervise lab technicians.

Benefits

• Flexible time off
• Robust learning resources
• Competitive compensation
• Competitive benefits
• Learning and development opportunities
• Comprehensive benefits such as; healthcare, wellness, financial, retirement, family support, continuing education, and time off benefits.

What This Job Offers

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