Note: The job is a remote job and is open to candidates in USA. TECHEAD is recruiting on behalf of an unnamed defense and secure communications manufacturer. The Senior Mechanical Engineer will lead full-lifecycle design, verification, and sustainment of ruggedized electronic enclosures and mission-critical hardware, with emphasis on thermal management, structural integrity, EMI/EMC shielding, and manufacturability.
Responsibilities
- Act as the lead mechanical authority for mission-critical electronic hardware deployed in defense, aerospace, and high-security settings
- Manage enclosure and platform architecture from initial requirement definition through volume manufacturing, covering:
- Custom chassis, frame assemblies, and COTS component integration
- Thermal management systems (passive conduction, forced convection, liquid cooling, and heat sinks)
- Structural resilience against high shock, random vibration, temperature extremes, moisture ingress, dust, and corrosive salt-fog environments
- Translate electrical and payload constraints into scalable, low-to-high volume manufacturable hardware solutions
- Design precision sheet metal and CNC-machined structures that support TEMPEST, low-emissions, and strict EMI/EMC attenuation strategies:
- Radio frequency (RF) shielded housings, access covers, and conductive seams
- Specialized EMI gasketing, bonding, and grounding paths
- Secure cable egress/ingress zones, connector isolation, and shielding barriers
- Coordinate with electrical and layout teams to align chassis geometry with PCB layout strategies for optimal electromagnetic mitigation and signal isolation
- Support strict physical signal separation (e.g., RED/BLACK architectures) through internal mechanical compartmentalization
- Generate complex 3D CAD models, sub-assemblies, and production-ready drawing packages utilizing ASME Y14.5 drafting standards
- Perform detailed tolerance stack-up analyses and apply Geometric Dimensioning & Tolerancing (GD&T)
- Conduct structural and thermal Finite Element Analysis (FEA) to validate mechanical integrity prior to prototyping
- Select compliant surface finishes, specialized materials, and hardware retention strategies suitable for long-lifecycle deployment
- Lead hands-on prototype integration, bench testing, and fit checks
- Coordinate mechanical participation in environmental stress and qualification testing (thermal cycling, shock, vibration, ingress protection, EMI/EMC)
- Define physical layout parameters for critical PCB components, including connector locations, high-dissipation ICs, and thermal interface materials (TIMs)
- Partner with PCB layout engineers on grounding topologies, component clearances, and thermal relief strategies
- Work alongside manufacturing teams to incorporate Design for Manufacturability/Assembly (DFM/DFA) principles, tooling considerations, and assembly streamlining
- Support supply chain teams on component sourcing, alternate material qualifications, and component obsolescence management
- Defend mechanical trade studies, risk assessments, and architectural choices during formal design reviews
- Author standard operating procedures, assembly documentation, and manufacturing test fixtures for production handoff
- Provide sustaining engineering support for deployed hardware, addressing field returns, engineering change orders (ECOs), and product upgrades
- Maintain rigorous configuration control and document management across the product lifecycle
Skills
- Bachelor's degree in Mechanical Engineering or a related discipline
- 7–10+ years of professional mechanical engineering experience, with a focus on electronic packaging and enclosure design
- Direct experience developing ruggedized electronics and chassis assemblies for defense or aerospace applications in accordance with applicable military/aerospace standards
- Solid technical background in:
- Electronics enclosure design (sheet metal, CNC machining, die casting, plastic injection molding)
- Board-level and system-level thermal management
- Mechanical design strategies for EMI/EMC shielding and environmental sealing
- Hands-on proficiency with modern 3D CAD software (SolidWorks preferred) and product data management / PLM tools
- Proven track record leading mechanical hardware platforms through the full lifecycle—from concept design to qualification and long-term sustainment
- Experience designing to aerospace and defense specifications (e.g., MIL-STD-810, MIL-STD-461, RTCA/DO-160, or equivalent)
- Hands-on background conducting EMI/EMC mechanical mitigation and participating in lab compliance testing
- Experience designing ruggedized systems subjected to extreme dynamic shock, vibration, and environmental exposure
Benefits
- This position is fully remote / work from home.
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