Principal Mechanical Engineer, Development

About the Role

BAE Systems is seeking a Principal Mechanical Engineer to join the Countermeasure & Electromagnetic Attack Solutions team in Merrimack, NH. This team provides next-generation threat detection and countermeasure solutions that enhance mission survivability for air, land, and naval warfighters. The role spans the full product lifecycle—business capture, development, production, testing, and sustaining—for a variety of complex defense products and technologies. You will collaborate with electrical, mechanical, software, firmware, and test engineers, as well as product managers and stakeholders, to develop solutions in an Agile hardware development environment.

The ideal candidate thrives in a learning environment that encourages leadership and technical growth, is detail-oriented, possesses strong analytical skills, and has a passion for continuous improvement. This position requires U.S. citizenship and full-time onsite work due to the nature of the role and collaboration requirements.

Responsibilities

• Lead mechanical engineering designs, development, integration/test, and production of complex and dynamic military systems.
• Generate 3D solid models, drawings, and documentation utilizing GD&T principles.
• Perform tolerance analyses to assure fit and function.
• Perform thermal, structural/stress, and modal/vibration analyses.
• Assess designs against environmental requirements.
• Develop prototypes and conduct test and verification efforts.
• Partner with other engineering disciplines and operations personnel to develop solutions adhering to DTUPC, DFT, and DFM requirements.
• Support resolution of technical issues discovered during manufacture and test of deliverable hardware.
• Evaluate and troubleshoot mechanical faults and issues, assessing test failures for root cause and identifying disposition/corrective actions.
• Design test equipment to ensure the performance and integrity of manufactured products.
• Participate in requirements development, technical trade studies, and evaluation of technology insertion/upgrades.
• Develop and execute test plans, including integration of test solutions, and provide detailed reports on test results.
• Participate in new business capture.

Requirements

• Bachelor's degree in Mechanical Engineering.
• 6+ years (or 2+ years with MS ME) designing, testing, and troubleshooting high-reliability mechanical systems.
• Demonstrated understanding of mechanical principles, test methodologies, and ability to work with advanced test equipment and cutting-edge technology.
• Strong “hands-on” laboratory experience with instrumentation, equipment, and processes.
• Eligible to obtain a DOD Security Clearance.

Preferred Qualifications

• Understanding of heat transfer principles, strength of materials, materials selection, and design for vibration environments.
• Experience with mechanical engineering tools for design and analysis, including ANSYS Workbench/Mechanical, PTC Creo, MATLAB/Simulink, Siemens NX, and ANSYS Icepak.
• Familiarity with design, analysis, and manufacturing standards for complex multilayer rigid and rigid-flex CCAs.
• Knowledge of engineering development processes for the aero/defense industry, including designing and testing to ASTM, SAE, DO, and MIL-STD-810.
• Experience with Agile hardware development and risk-reduction prototyping.
• Control account management experience.
• Experience with LRIP/FRP, especially electronics manufacturing and test methodologies.
• Familiarity with AS9145 compliant processes.
• Strong written and verbal communication skills.
• Active DOD security clearance.

Pay

Full-Time Salary Range: $118,095 - $200,762. Individual salaries are determined by factors including business considerations, local market conditions, internal equity, and candidate qualifications such as skills, education, and experience.

Benefits

Regular employees scheduled to work 20+ hours per week are offered:

• Health, dental, and vision insurance.
• Health savings accounts.
• 401(k) savings plan.
• Disability coverage and life and accident insurance.
• Employee assistance program and legal plan.
• Discounts on home, auto, and pet insurance.
• Paid time off, paid holidays, and other leave programs, including paid parental, military, bereavement, and applicable federal and state sick leave.
• Company recognition program with monetary or non-monetary awards.
• Other incentives based on position level and job specifics.

About BAE Systems Electronic Systems

BAE Systems, Inc. is the U.S. subsidiary of BAE Systems plc, an international defense, aerospace, and security company delivering products and services for air, land, and naval forces, as well as advanced electronics, security, information technology solutions, and customer support services. Electronic Systems (ES) is the global innovator behind game-changing defense and commercial electronics, pushing the limits of technology to give customers a competitive edge. With over 14,000 employees, ES impacts global security and communities through breakthrough technology and superior products.