Sr Mechanical Engineer

Albers Aerospace•McKinney, TX

5d•Hybrid

About The Position

The Senior Mechanical Engineer will lead the design, development, and rapid integration of mechanical systems supporting advanced defense applications, including unmanned systems, sensor payloads, and mission-critical hardware. This role requires a hands-on engineer capable of moving quickly from concept to prototype to fieldable system, often under compressed timelines and evolving requirements. The ideal candidate thrives in fast-paced environments, balances analytical rigor with practical execution, and is comfortable working across multidisciplinary teams to deliver integrated solutions.

Requirements

Bachelor’s degree in Mechanical Engineering or related field (Master’s preferred)
8+ years of experience in mechanical design, preferably in aerospace or defense
Strong proficiency in CAD tools (e.g., SolidWorks)
Experience with rapid prototyping methods (CNC, 3D printing, sheet metal, composites)
Familiarity with environmental and durability requirements for defense systems
Ability to work hands-on in a lab or integration environment
U.S. Citizenship and ability to obtain/hold a security clearance

Nice To Haves

Experience with UAVs, missiles, sensor systems, or payload integration
Knowledge of thermal management for electronics and high-power systems
Experience designing for harsh environments (vibration, shock, temperature extremes)
Familiarity with MIL standards (e.g., MIL-STD-810, MIL-STD-461)
Experience supporting live testing or operational deployments
Background in lightweight structures, composites, or sealed enclosures

Responsibilities

Lead mechanical design of complex assemblies, including enclosures, mounting structures, thermal solutions, and structural components for defense systems
Develop designs from concept through detailed design, prototype fabrication, and test
Perform trade studies to balance weight, strength, thermal performance, manufacturability, and cost
Create and maintain 3D CAD models, drawings, and technical data packages (TDPs)
Drive rapid build-test-iterate cycles with a focus on speed and performance
Support hands-on integration of hardware into platforms (e.g., UAVs, ground systems, sensor pods)
Work closely with electrical, systems, and software engineers to ensure seamless integration
Troubleshoot mechanical and system-level issues during lab and field testing
Conduct structural, thermal, and vibration analyses (FEA/hand calculations)
Support environmental qualification aligned with standards such as MIL-STD-810
Develop and execute test plans to validate mechanical performance and durability
Interface with fabrication resources (machine shops, additive manufacturing, vendors)
Ensure designs are manufacturable and support low-rate initial production (LRIP)
Support design for manufacturability (DFM) and design for assembly (DFA)
Support program milestones including SRR, PDR, CDR, and test readiness reviews
Provide technical leadership within Integrated Product Teams (IPTs)
Estimate effort, identify risks, and propose mitigation strategies
Contribute to proposal efforts and technical planning for new programs