Principal Mechanical Engineer, Development (Sign On Bonus Available)

About the role

BAE Systems is seeking a Senior Mechanical Engineer to join the Countermeasure & Electromagnetic Attack Solutions team in Nashua, NH. This 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 next-generation threat detection and countermeasure solutions that enhance mission survivability for air, land, and naval warfighters.

The ideal candidate thrives in Agile hardware development environments, advocates for risk-reduction prototyping, and follows requirements-driven design and verification. This position is full-time onsite due to the need for consistent, in-person collaboration and the nature of the work.

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 4+ 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, 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
• Agile hardware development experience
• 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
• 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/state sick leave)
• Company recognition program with monetary or non-monetary awards
• Other incentives based on position level and job specifics