Senior Principal Mechanical Engineer, Development (Sign On Bonus Available)

About the role

BAE Systems is seeking a Senior Principal Mechanical Engineer to join the Countermeasure & Electromagnetic Attack Solutions team in Nashua, NH. This team provides next-generation threat detection and countermeasure solutions that deliver unparalleled electronic warfare capabilities to enhance mission survivability. 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 closely with electrical, mechanical, software, firmware, and test engineers, as well as product managers and stakeholders, to develop high-performance solutions in an Agile hardware development environment. The ideal candidate thrives in a learning environment that encourages leadership and technical growth, with a strong focus on risk-reduction prototyping, requirements-driven design, and verification.

This is a hybrid position, with work performed both onsite and remotely.

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 ensure fit and function.
• Conduct 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, assess test failures for root cause, and identify disposition/corrective actions.
• Design test equipment to ensure the performance and integrity of manufactured products.
• Participate in requirements development, perform technical trade studies, and evaluate 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 efforts.

Requirements

• Bachelor's degree in Mechanical Engineering.
• 8+ years (or 6+ years with an MS in Mechanical Engineering) of experience designing, testing, and troubleshooting high-reliability embedded systems.
• Demonstrated understanding of mechanical principles, test methodologies, and experience with advanced test equipment and cutting-edge technology.
• Strong “hands-on” laboratory experience with instrumentation, equipment, and processes.
• Active 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 standards.
• Experience leading cross-functional engineering teams to develop prime mission equipment or test equipment through various stages of development cycles.
• Agile hardware development experience and a self-starter mindset.
• Exceptional ingenuity, creativity, and resourcefulness.
• Control account management experience.
• Experience with LRIP/FRP, particularly in electronics manufacturing and test methodologies.
• Familiarity with AS9145 compliant processes.
• Strong written and verbal communication skills.

Pay

Full-Time Salary Range: $132,962 – $226,035. 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.
• Additional incentives may be available based on position level and job specifics.