Senior Mechanical Engineer - Structural/Thermal Analysis

About the role

We are seeking an experienced Mechanical Engineer with strong skills in structural analysis, thermal analysis, and finite element analysis (FEA) to support a wide range of products across the BAE Systems Aerospace and Mission Systems segment. This is a full‑time analysis position focused on structural and thermal modeling, simulation, and engineering assessment. This role supports multiple business areas and includes work on electronics, EO/IR systems, RF components, precision mechanisms, and mission‑critical hardware. As part of the Mechanical Analysis Capability Group, you will join a cross‑sector team of full‑time analysts who apply advanced engineering and simulation methods to understand, model, and predict mechanical behavior across diverse product lines. Senior candidates will provide technical leadership for complex analysis challenges and influence early architecture and major design decisions. Candidates who enjoy hands‑on analysis, modeling, and practical engineering judgment will excel in this role.

Responsibilities

• Provide expert‑level technical leadership for complex structural and thermal analysis challenges, influencing early architecture and major design decisions.
• Define analysis objectives and approaches for ambiguous or first‑of‑kind technical problems with minimal guidance.
• Perform structural and thermal analyses using both classical engineering methods and industry‑standard FEA tools.
• Create and post‑process finite element models from component‑level to system‑level using tools such as Siemens Simcenter 3D/NX, NASTRAN, Ansys Mechanical, and Ansys Icepak.
• Execute modal, vibration, shock, static, steady‑state, and transient thermal analyses.
• Collaborate with multidisciplinary design teams to optimize system performance, reliability, and manufacturability.
• Lead analysis planning and technical reviews; mentor and guide junior engineers across programs.
• Communicate analysis results, technical recommendations, and risk assessments to internal and external stakeholders.
• Support program execution both onsite and remotely.

Requirements

• Bachelor’s Degree in Mechanical or Aerospace Engineering and 8+ years of relevant experience.
• Demonstrated experience in FEA, modal and vibration analysis, shock, and static analysis of structures.
• Experience performing steady‑state and transient heat transfer modeling.
• Ability to simplify complex problems into efficient analysis approaches that provide clear, actionable feedback.
• Strong communication skills and ability to work effectively in both onsite and remote team environments.
• Eligibility to obtain a DoD Security Clearance at the “Secret” level.

Preferred Qualifications

• Master’s Degree in Mechanical or Aerospace Engineering and 8+ years of relevant experience.
• Experience with industry standard pre/post processors such as Simcenter 3D, Femap, ANSYS Workbench, ANSYS Mechanical, Hypermesh, etc.
• Experience with solvers such as NASTRAN, Abaqus, ANSYS, LS‑Dyna, RADIOSS, Optistruct, etc.
• Knowledge of structural and thermal design of electronics.
• Familiarity with composite materials and printed circuit board technologies.
• Experience evaluating structural fatigue and solder joint reliability (creep, vibration fatigue, shock).
• Familiarity with STOP analysis (Structural, Thermal, Optical Performance) using tools such as SigFit.
• Active Secret clearance.

Pay

Full‑Time Salary Range: $132,962 – $226,035

This range is based on our market pay structures. Individual salaries are determined by a variety of factors including, but not limited to: business considerations, local market conditions, internal equity, and candidate qualifications such as skills, education, and experience.

Benefits

• Health, dental, and vision insurance
• Health savings accounts
• 401(k) savings plan
• Disability coverage
• Life and accident insurance
• Employee assistance program
• Legal plan
• Discounts on home, auto, and pet insurance
• Paid time off and paid holidays
• 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/or job specifics

Schedule

Hybrid role requiring at least 50% onsite presence.