Mechanical Engineer

Actalent is seeking a Mechanical Engineer to serve as a technical leader for the design, development, and integration of complex mechanical systems supporting unmanned aerial and unmanned surface vehicle platforms.

About the role

You will own major mechanical subsystems and contribute to overall vehicle architecture, ensuring designs meet performance, reliability, manufacturability, and cost objectives. Operating with a high degree of autonomy, you will bridge early concept development with deployable, production-ready capabilities while collaborating closely with aerospace, electrical, and manufacturing teams. This role involves developing innovative solutions across propulsion systems, structural components, payload integration, and launch mechanisms, while mentoring junior engineers and advancing next-generation unmanned and autonomous systems.

Responsibilities

• Lead the design and development of complex mechanical subsystems for unmanned aerial vehicles (UAVs) and unmanned surface vehicles (USVs).
• Own the mechanical architecture, layout, and system integration for major vehicle subsystems, ensuring cohesive performance and reliability.
• Contribute to propulsion system design and integration, including engines and associated mechanical systems.
• Perform and review engineering analyses to validate performance, structural integrity, thermal behavior, and overall reliability of mechanical designs.
• Review and refine designs for structural elements such as wings, tails, fuselage, and other aerodynamic surfaces, focusing on their interaction with the airstream.
• Design and implement stiffening structures, manipulate control surfaces, and package sensors to meet structural and aerodynamic requirements.
• Optimize cable routing, component packaging, and mechanical interfaces to improve maintainability, manufacturability, and system robustness.
• Oversee prototype fabrication, mechanical assembly, and system-level integration activities.
• Lead troubleshooting efforts during lab testing, ground testing, and field operations, resolving mechanical and integration issues efficiently.
• Evaluate materials, manufacturing methods, and supply chain options to optimize cost, weight, performance, and scalability.
• Collaborate closely with aerospace, electrical, and manufacturing engineering teams to ensure cohesive vehicle system design and integration.
• Contribute to innovative mechanical solutions, including payload integrations, launch systems, and structural systems for unmanned platforms.
• Support the development and implementation of advanced manufacturing approaches such as additive manufacturing, 3D printing, and rapid prototyping.
• Mentor junior engineers, providing technical guidance and supporting the development of engineering standards, best practices, and design documentation.
• Participate in technical planning, design reviews, and program execution across multiple vehicle programs, providing expert mechanical engineering input.
• Document designs, analyses, test results, and design changes in a clear and traceable manner to support production and future upgrades.

Requirements

• Bachelor’s degree in Mechanical Engineering or a closely related field.
• 5+ years of experience in mechanical engineering, with a focus on engine design and prototyping, preferably in the aerospace or automotive industry.
• Strong understanding of thermodynamics, fluid mechanics, and propulsion systems.
• Proficiency in CAD software such as SolidWorks or CATIA for detailed mechanical design and component packaging.
• Experience using simulation and analysis tools such as ANSYS and MATLAB for structural, thermal, and performance analyses.
• Demonstrated experience in designing structural elements including wings, tails, fuselage components, and stiffening structures for dynamic environments.
• Hands-on experience with mechanical system integration, including control surfaces, sensor packaging, and cable routing optimization.
• Strong analytical and problem-solving abilities with keen attention to detail and design quality.
• Excellent verbal and written communication skills, with the ability to effectively collaborate with multidisciplinary engineering teams and stakeholders.
• Ability to thrive in a fast-paced, dynamic environment and adapt to changing priorities and project requirements.
• Ability to travel domestically and internationally as needed for testing, integration, or program support.

Skills

• Experience with advanced manufacturing techniques, including additive manufacturing, 3D printing, and rapid prototyping.
• Familiarity with mechanical design for unmanned aerial vehicles (UAVs) and unmanned surface vehicles (USVs).
• Experience in evaluating materials and manufacturing methods to balance cost, weight, and performance.
• Experience participating in formal design reviews and technical planning for complex engineering programs.
• Interest in mentoring and developing junior engineers, and in contributing to engineering standards and best practices.
• Comfort working with minimal bureaucracy in an environment that values engineering judgment and technical ownership.

Work Environment

This role operates in a well-funded, agile engineering environment that emphasizes technical ownership, rapid iteration, and practical innovation. Engineers work on mission-critical, nationally significant programs and are trusted with real responsibility and creative freedom, without constant customer oversight. The team has direct access to advanced tools and technologies, including in-house 3D printing and other rapid prototyping capabilities, enabling quick design cycles and reduced dependence on external supply chains.

The Rockville team currently consists of a small, focused group of mechanical engineers at varying experience levels, fostering close collaboration and knowledge sharing. The organization offers flexible work hours and a 9/80 work schedule, supporting work-life balance while maintaining a fast-paced, results-oriented culture where engineers can move quickly, innovate, and see the visible impact of their contributions.

Pay

The pay range for this position is $42.00 - $80.00/hr. Individual compensation offered for this position within this range will depend on many factors, including qualifications, skills, relevant experience, job knowledge, geographic location, internal equity, and other pertinent job-related factors.

Benefits

Eligibility requirements apply to some benefits and may depend on your job classification and length of employment. Benefits are subject to change and may be subject to specific elections, plan, or program terms. If eligible, the benefits available for this temporary role may include the following:

• Medical, dental & vision
• Critical Illness, Accident, and Hospital
• 401(k) Retirement Plan – Pre-tax and Roth post-tax contributions available
• Life Insurance (Voluntary Life & AD&D for the employee and dependents)
• Short and long-term disability
• Health Spending Account (HSA)
• Transportation benefits
• Employee Assistance Program
• Time Off/Leave (PTO, Vacation or Sick Leave)

Schedule

This is a Contract position based out of Rockville, MD, with a 9/80 work schedule. The role is fully onsite.