Structural and Thermal Design and Test Engineer

BAE Systems•Cedar Rapids, IA

25d•$88,189 - $149,922•Hybrid

About The Position

BAE Systems is seeking a Senior Mechanical Engineer specializing in Thermal and Structural Design and Test. This role is critical to the physical validation and reliability of complex hardware, ensuring that components and assemblies can withstand all anticipated operational and environmental loads—including static, dynamic, heat transfer, and environmental stresses—without failure. Unlike a pure analysis role, this position bridges the gap between design and physical verification. The successful candidate will be responsible for the mechanical architecture and structural/thermal integrity of hardware while directly overseeing environmental lab activities. This includes the operation of vibration shaker tables and temperature chambers, as well as the development of customized test profiles to simulate real-world operational environments. The engineer will serve as a key technical resource, mentoring hardware engineering teams in structural and thermal design best practices and coordinating the execution of comprehensive temperature and vibration test efforts.

Requirements

Bachelor’s degree in Mechanical Engineering.
3+ years of experience in mechanical engineering, with a strong emphasis on physical testing and hardware validation.
Strong understanding of structural design best practices and the ability to apply them to complex hardware assemblies.
Familiarity with heat transfer and structural mechanics principles to support design and validation efforts.
A motivated self-starter capable of troubleshooting test failures and implementing corrective design actions.
Strong written and verbal communication skills for documenting test results and presenting findings to leadership.

Nice To Haves

Proven experience in the operation and management of environmental test equipment (vibration shakers, thermal chambers).
Hands-on experience developing and executing temperature and vibration test plans.
Ability to develop custom test fixtures and environments for dynamic and thermal validation.

Responsibilities

Lead and oversee environmental lab activities, including the operation of vibration shaker tables and temperature/humidity chambers.
Develop and create customized temperature and vibration profiles designed to simulate real-world operational environments and military specifications.
Coordinate and execute temperature and vibration test efforts to validate hardware performance and design requirements.
Develop customized thermal and dynamic test environments (fixtures, mounting, and instrumentation) to ensure accurate data collection.
Drive the mechanical architecture, structural integrity, and thermal stability of complex hardware and assemblies.
Ensure all hardware is designed to withstand operational loads, including static, dynamic, and environmental stresses.
Perform necessary thermal and structural analyses to support design decisions, validate design margins, and predict potential failure modes.
Act as a mentor to Hardware Engineering Teams, providing guidance on structural and thermal design best practices to improve first-pass success rates.
Establish guidelines for physical validation and design-for-test (DFT) principles across projects.
Collaborate closely with Hardware Engineering, System Engineering, and Program Management teams to ensure mechanical constraints are integrated into the overall system design.