Sr Principal Mechanical Engineer, Control Actuation Systems

Posted September 10, 2026 – Huntsville, AL (onsite). U.S. citizenship and active transferable Secret DoD clearance required.

About the role

The Precision Control Actuation System (PCAS) department at Raytheon seeks an expert mechanical engineer to support the development, build, and verification of control actuation systems. The role involves working on integrated product teams, providing mechanical engineering support that may include detailed design, earned value management, test design and execution, and systems engineering, while adapting to fluctuating program needs. The position offers hands‑on hardware work, access to engineering fellows, and a strong technical learning environment.

Responsibilities

• Work autonomously with expert or mastery‑level knowledge in control mechanism development.
• Exercise strategic vision to influence functional and organizational strategies of the PCAS organization.
• Provide mechanical engineering support including detailed mechanical design, earned value management, test design and execution, and systems engineering.
• Flex responsibilities based on current organizational needs and skill sets.
• Participate in lab activities: engineering builds, hardware integration, hardware tuning, and hardware verification.
• Engage with engineering fellows for accelerated technical growth.

Requirements

• U.S. citizenship.
• Active and transferable U.S. government‑issued Secret security clearance (or ability to obtain interim clearance) prior to start date.
• Degree in a STEM field and minimum 10 years of relevant experience, OR an advanced degree in a related field and minimum 7 years of experience.
• Minimum 10 years of experience in mechanical engineering design.

Skills

• Experience with systems or mechanical engineering of servo controls.
• Experience developing CAS requirements, architecture, risk, verification & validation, system performance & function, safety and environmental compliance.
• Experience with control actuation systems using permanent‑magnet brush and brushless DC motor technology.
• Experience with feedback control systems: sizing, testing, integration, design‑for‑manufacturing, kinematic and dynamic simulation and analysis.
• Proficient in Geometric Dimensioning and Tolerancing per ASME Y14.5.
• Proven ability to deconstruct higher‑level tasks into discrete work packages.
• Proficient in generating free‑body diagrams.
• Proficient in engineering processes and procedures.
• Moderate 3D modeling skills with a prominent commercial package.
• Experience with Pro/Engineer/CREO 3D modeling and mechanical drawing generation.
• Experience using MATLAB, Simulink, and dSpace.
• Proven design and manufacturing knowledge in machined parts, injection‑molded parts, hobbing, broaching, sheet metal fabrication, BLDC motors, wire/harnesses, corrosion‑resistant steels and aluminum alloys.

Benefits

• Medical, dental, and vision insurance.
• Life insurance.
• Short‑term and long‑term disability.
• 401(k) match.
• Flexible spending accounts.
• Flexible work schedules.
• Employee assistance program.
• Employee Scholar Program.
• Parental leave.
• Paid time off and holidays.
• Annual short‑term and/or long‑term incentive compensation programs (eligibility based on position level and collective‑bargaining coverage).

Pay

The salary range for this role is $132,400 – $251,600 USD.

Schedule

Onsite position.