Senior Mechanical Engineer - Principal Investigator

About the role

Torch Technologies is seeking a Senior Mechanical Engineer - Principal Investigator to lead the design, analysis, development, testing, and integration of complex mechanical systems and structures.

Responsibilities

• Technical Leadership
  • Lead the design and development of mechanical systems, structural assemblies, and machine components from concept through production.
    • Provide technical oversight for structural, dynamic, vibration, shock, thermal, fatigue, and reliability analyses.
    • Review and approve engineering calculations, analysis reports, trade studies, and technical documentation.
    • Establish design requirements, verification methods, and acceptance criteria.
    • Lead design reviews (SRR, PDR, CDR, PRR) and support prototype development, testing, qualification, and production transition activities.
    • Support root-cause investigations and corrective actions.
  • Engineering Management
    • Cookordination multidisciplinary engineering efforts across mechanical, electrical, software, manufacturing, and systems engineering teams.
    • Manage schedules, resources, budgets, and technical performance.
    • Establish engineering processes, standards, and best practices.
    • Review engineering deliverables, technical data packages, and structural assessments to ensure design integrity and compliance.
    • Support design improvements through technical reviews, failure analysis, and corrective action implementation.
  • Documentation & Business Development
    • Ensure compliance with documentation, configuration management, and change control requirements.
    • Develop technical content for proposals, presentations, white papers, and customer briefings.
    • Support capture efforts, proposal development, customer engagements, technical reviews, and strategic growth initiatives.

Requirements

• U.S. Citizenship.
• Bachelor's degree in Mechanical Engineering or related discipline with 10+ years of relevant experience; OR Master's degree in Mechanical Engineering or related discipline with 8+ years of relevant experience.
• Active security clearance.
• Experience leading engineering teams and technical projects.
• Experience with SolidWorks, SolidWorks PDM, and FEA tools such as SolidWorks Simulation and NASTRAN.
• Strong understanding of machine design, structural mechanics, materials engineering, manufacturing processes, and finite element methods.
• Experience developing engineering documentation and technical data packages.
• Proven ability to interface with customers and senior leadership.
• Strong written and verbal communication skills.

Preferred Qualifications

• Master's degree in Mechanical Engineering, Aerospace Engineering, or related field.
• Experience supporting defense, aerospace, robotics, or advanced manufacturing programs.
• Experience with Creo, CATIA, or similar CAD software.
• Knowledge of military, aerospace, ASME, AWS, and AISC standards.
• Experience with DFM, DFA, reliability engineering, and MBSE methodologies.

Preferred Technical Skills

• Structural analysis and finite element analysis (FEA).
• Machine design and mechanical system integration.
• GDT, CAD modeling, and tolerance analysis.
• Materials selection and manufacturing processes.
• Mechanical testing, qualification, and failure analysis.
• Engineering documentation, proposal development, and technical leadership.

Schedule

• Monday–Friday, 8:00 AM – 5:00 PM.
• Work Location: On-site, Huntsville, Alabama.
• Travel: Up to 15% as required.

Benefits

• ESOP participation.
• 401(k) match and safe-harbor contribution.
• Medical, dental, vision, life insurance, short-term disability, long-term disability.
• Flexible spending accounts, Health Saving Accounts and Health Reimbursement Accounts.
• EAP.
• Education assistance.
• Paid time off.
• Holidays.