26-00054J Mechanical Engineer III

Mechanical Engineer III – Industrial Automation & Prototype Development

Location: Merrifield, VA (Onsite)

Design. Build. Solve.

Do you enjoy taking an idea from a sketch to a working prototype? Are you the engineer others rely on when complex equipment needs a practical solution?

Join our team supporting the U.S. Postal Service Engineering Headquarters, where you'll help improve one of the largest automated package sorting networks in the country. As a Mechanical Engineer III, you'll design, prototype, troubleshoot, and modernize the equipment that keeps millions of packages moving every day.

This is more than a design role—you'll spend time in the engineering lab, machine shop, and field turning concepts into real-world solutions.

What You'll Do

As part of the Package Sorting Technology Group, you'll:

• Design, fabricate, machine, weld, and assemble mechanical and electrical prototypes
• Create custom fixtures, tooling, brackets, carts, test equipment, and ergonomic workstations
• Design mechanical components and assemblies using 3D CAD software
• Evaluate and replace obsolete (End-of-Life) components used in automated package sorting equipment
• Engineer retrofit solutions that improve equipment reliability, safety, and performance
• Troubleshoot mechanical, pneumatic, electrical, and automation issues affecting production systems
• Perform root cause analysis to eliminate recurring equipment failures and operational bottlenecks
• Design custom tools and semi-automated equipment that improve productivity and reduce operator fatigue
• Participate in engineering design reviews and collaborate with project managers, suppliers, maintenance teams, and safety personnel
• Conduct field inspections and develop Modification Work Orders (MWOs) for equipment upgrades deployed nationwide

What We're Looking For

Required Qualifications

• Bachelor's degree in Mechanical Engineering or a related engineering discipline
• 4+ years of mechanical engineering experience
• Experience supporting industrial automation, material handling systems, manufacturing equipment, or conveyor systems
• Hands-on experience with prototype fabrication, machining, welding, and mechanical assembly
• Proficiency with 3D CAD modeling and engineering drawings
• Experience interpreting fabrication prints and GD&T
• Knowledge of pneumatic systems and industrial mechanical equipment
• Strong troubleshooting, analytical, and root cause analysis skills
• Experience creating technical documentation, retrofit instructions, or engineering procedures

Preferred Qualifications

• Experience with package, parcel, mail, or logistics automation systems
• Experience designing industrial grounding or static mitigation systems
• Knowledge of industrial electrical circuits, E-stop systems, or LED indicator controls
• Experience documenting engineering projects using drone photography or video
• Familiarity working with OSHA, safety, or facility engineering teams

Why Join Our Team?

You'll work on engineering projects that have a direct impact on the nation's postal infrastructure. Your ideas won't stay on paper—you'll design, build, test, and deploy solutions used in USPS facilities across the country.

What We Offer

• Competitive Salary
• Medical, Dental & Vision Insurance
• 401(k) Retirement Plan
• Life Insurance
• Short-Term & Long-Term Disability
• Paid Vacation, Sick Leave & Company Holidays
• Paid Parental Leave
• Professional Development & Training
• Opportunity to work on large-scale industrial automation projects

Additional Information

• Location: Merrifield, VA
• Schedule: Monday–Friday, 8:00 AM–5:00 PM
• Travel: Less than 10%
• Occasional evening or weekend support may be required
• Must successfully pass a pre-employment background check and drug screening.

Ready to build solutions that keep America moving? Apply today and become part of a team that's engineering the future of package automation.