Sr. Principal Mechanical Engineer - Castings - ALE
About The Position
The Air Launched Effectors All Up Round (ALE AUR) Mechanical Design organization is seeking a highly experienced Senior Principal Mechanical Engineer (P5) with casting technologies experience. The engineer will provide technical direction, engineering rigor, and execution oversight to deliver producible, affordable, high-performance mechanical solutions aligned with program objectives, Hardware Engineering standards, and Raytheon engineering processes. The role drives engineering excellence, design reuse, and producibility across a large, multidisciplinary mechanical engineering team. It involves close collaboration with Program Management, Systems Engineering, Operations, Supply Chain, and mechanical teams covering Airframe, Mechanisms, Propulsion, Avionics, Configuration Management, Data Management, and Support Equipment within Hardware Engineering. The position is onsite in Tucson, Arizona, and requires domestic travel to casting and machining suppliers up to 75%. An active and transferable U.S. government security clearance is required prior to the start date; candidates must be U.S. citizens and able to obtain an interim clearance before starting.
Requirements
- Typically requires a STEM degree and at least 10 years of relevant experience, or an advanced degree in a related field and at least 7 years of experience.
- Experience in a technical leadership role with exposure to the full development lifecycle.
- Experience with aluminum casting and machining processes.
- Ability and willingness to travel domestically to casting and machining suppliers up to 75%.
- Experience leading and conducting trade studies; developing designs and requirements; and supporting integration and test of mechanical products.
- Experience with First Article Inspection (FAI).
- Experience with ANSI/ASME Y14.5 GD&T and tolerance analysis.
- Proficiency in CREO (Pro/E) or similar 3D CAD solid-modeling tools.
- Experience working with suppliers that deliver mechanical products, machined parts, and electronics.
- Experience supporting development and production programs for military applications.
- Ability to review and interpret technical documentation in a production environment.
- Experience supporting full-rate production of missile components and assemblies.
- Experience creating mechanical drawings or engineering documentation.
- Ability to work across multiple functional and disciplinary organizations to resolve technical challenges.
- Ability to work autonomously with minimal supervision.
- Active and transferable U.S. government-issued security clearance required before starting; must be able to obtain an interim clearance before starting.
- U.S. citizenship, as only U.S. citizens are eligible for the required security clearance.
Nice To Haves
- Strong communication skills and ability to present complex technical concepts clearly.
- Experience preparing technical proposals and delivering technical presentations.
- Engineering experience across the full missile product lifecycle.
- Knowledge of Technical Data Package development and compliance.
- Experience supporting manufacturing and supplier engagements.
- Familiarity with USG, DCMA, or customer involvement during development and sell-off activities.
- Demonstrated collaboration, problem-solving ability, and a process-improvement mindset.
Responsibilities
- Perform mechanical design, development, and documentation of components, sub-assemblies, and major end items in accordance with system requirements.
- Lead and mentor mechanical engineering teams while meeting schedule, financial, and technical objectives.
- Collaborate with structural and thermal analysts, materials engineering, quality, safety, supply chain, operations, and program leadership to develop and refine design solutions.
- Support factories and suppliers with product development, integration, troubleshooting, and obsolescence management, domestically and internationally.
- Conduct trade studies, participate in design peer reviews, and resolve technical action items.
- Apply thermal, structural, dynamic, and reliability analysis results to improve mechanical designs.
- Apply GD&T principles, including performing and reviewing tolerance analyses to ensure proper form, fit, and function.
- Improve designs using DFMA and producibility principles.
- Develop and maintain the technical data package (TDP), ensuring capabilities and requirements compliance.
- Serve as responsible engineer or subsystem lead, directing and reviewing team members’ work with limited supervision.
- Use Raytheon hardware tools, processes, and standards across all phases of development.
- Support First Article Inspection (FAI) and Raytheon Source Inspection (RSI) in partnership with Quality Engineering.
- Contribute to contract-funded and internal research projects at varying stages of proposal, design, and integration/test.
Benefits
- Medical insurance
- Dental insurance
- Vision insurance
- Life insurance
- Short-term disability
- Long-term disability
- 401(k) match
- Flexible spending accounts
- Flexible work schedules
- Employee assistance program
- Employee Scholar Program
- Parental leave
- Paid time off
- Holidays
- Annual short-term and/or long-term incentive compensation programs may be available, depending on position level and collective-bargaining coverage.
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What This Job Offers
Job Type
Full-time
Career Level
Senior
