Senior Principal Mechanical Engineer, Development (Sign On Bonus Available)

BAE Systems•Nashua, NH

7d•$132,962 - $226,035•Hybrid

About The Position

BAE Systems is seeking a Senior Principal Mechanical Engineer to join its Countermeasure & Electromagnetic Attack Solutions team in Nashua, New Hampshire. The team develops threat detection and countermeasure solutions for electronic warfare and mission survivability. This role spans the product lifecycle, including business capture, development, production, testing, and sustaining, and involves collaboration with electrical, mechanical, software, firmware, and test engineers, product managers, and other stakeholders. The engineer will lead mechanical design, development, integration, testing, and production for complex military systems. The position emphasizes Agile hardware development, risk-reduction prototyping, requirements-driven design and verification, and ensuring product performance, quality, and reliability through design, analysis, and testing. Work is hybrid, with duties performed both onsite and remotely.

Requirements

Bachelor's degree in Mechanical Engineering.
8 or more years of experience designing, testing, and troubleshooting high-reliability embedded systems, or 6 or more 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 these 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 design and testing to ASTM, SAE, DO, and MIL-STD-810.
Experience leading a cross-functional engineering team in developing prime mission equipment or test equipment through development cycles.
Agile hardware development experience.
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 dispositions 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, integrate test solutions, and provide detailed reports on test results.
Participate in new business capture.