Senior Mechanical Engineer Analyst

DRS Daylight Solutions business provides industry-changing mid-infrared laser light technology for government and commercial markets, including defense and security, life sciences, and industrial process control. As a mid-IR technology pioneer, Daylight Solutions has delivered more mid-IR systems to more applications worldwide than any other company.

About the Role

The Senior Mechanical Engineer Analyst - Simulation and FEA performs advanced simulation and analysis to predict structural, thermal, and coupled physics behavior of assemblies and instruments. Work includes developing models, defining load cases, executing analyses, correlating to test when available, and translating results into design actions and verification evidence. The role supports issue resolution and design closure across the business by building and validating models that explain real behavior and quantify margin. Outputs are engineering artifacts that enable requirement closure, qualification readiness, and stable production.

Responsibilities

• Build, verify, and run structural models for linear and nonlinear statics and dynamics.
• Define critical load scenarios and boundary conditions that represent real use, handling, and environmental conditions.
• Produce engineering artifacts that state assumptions, inputs, solver setup, sensitivities, and conclusions suitable for review and reuse.
• Develop thermal models to predict temperatures, gradients, and thermal stability. Quantify thermal sensitivities that affect alignment, packaging stability, and operating margin.
• Execute coupled loads analyses where mechanical, thermal, and flow effects interact.
• Support Structural Thermal Optical Performance (STOP) analysis when optical performance is sensitive to structural and thermal behavior.
• Perform CFD and flow analysis to support convective cooling, purge flows, and enclosure thermal behavior as needed.
• When unexpected failures occur, use simulation to bound root cause hypotheses, identify critical variables, and recommend design or process changes.
• Partner with Manufacturing Engineering and Product Engineering to translate findings into controlled changes with measurable outcomes.
• When test data exists, correlate models to reality and quantify uncertainty and margin. Define what test data is needed to close gaps in model fidelity and support verification.
• Work with Mechanical, Optical, EE, Firmware, Software, and Manufacturing teams to ensure simulation results translate into design decisions, verification plans, and integration closure.

Skills

• Proficiency with ANSYS toolchain for the analyses in this role, including ANSYS Mechanical (Structural), ANSYS Workbench, ANSYS APDL, ANSYS Icepak (electronics cooling), and ANSYS Fluent (CFD), with the ability to build, solve, post-process, and package review-ready engineering artifacts.
• Experience with SigFit for FEA-to-optics deformation fitting is desired.
• Working-level familiarity with Zemax for interpreting optical sensitivity and STOP-related handoffs.
• Experience with nonlinear mechanics, dynamics, and model-based failure investigation.
• Experience with thermal modeling and coupled thermo-mechanical analyses.
• Experience with CFD and flow modeling for cooling and enclosure behavior.
• Experience with specialized analyses such as Structural Thermal Optical Performance, optical sensitivity drivers, or other multi-domain performance modeling.

Qualifications

• BS in Mechanical Engineering or equivalent technical discipline and a minimum of 5 years of experience.
• Master’s degree or PhD in Mechanical Engineering, Aerospace Engineering, Applied Mechanics, or a closely related field may be considered in lieu of some required years of industry experience, provided the candidate demonstrates applicable simulation and analysis depth and the ability to generate review-ready engineering artifacts.
• Demonstrated experience performing engineering simulation with a focus on FEA.
• Ability to translate ambiguous field or factory issues into structured load cases, models, and actionable conclusions.
• Strong written and verbal technical communication with the ability to present analysis in formal reviews.
• U.S. Citizenship required.
• This position requires an active DOD security clearance or the ability to obtain such clearance within a reasonable time after commencement of employment.

Pay

The salary range for this position is $107,089.00/year - $159,027.00/year. This range reflects the good faith estimate of pay the employer is willing to offer at the time of posting. Several factors can influence the pay scale, including federal contract labor categories and contract wage rates, collective bargaining agreements, geographic location, business considerations, scope and responsibilities of the position, local or other applicable market conditions, and internal equity. Other factors include the candidate’s qualifications such as prior work experience, specific skills and competencies, education/training, and certifications.

Benefits

• Comprehensive health insurance (medical, dental, vision).
• Employer matching 401(k) retirement plan.
• Paid time off including vacation, holidays, and sick leave (including any state-mandated paid sick leave).
• Parental leave benefits.
• Tuition reimbursement and professional development support.
• Life and disability insurance coverage.
• Company contribution to a health savings account.
• Telemedicine services.
• Legal insurance.
• Annual performance-based bonuses and equity awards (for eligible employees).
• Overtime pay (for non-exempt employees as applicable).
• Wellness programs focusing on physical, emotional, and financial well-being.
• Flexible work schedules with a 9/80 program.
• Community service hours.