Principal Mechanical Engineer

Job Summary:

Mercury Systems is seeking the best and brightest engineering talent to help us deliver cutting‑edge technology for mission‑critical aerospace and defense applications, advancing innovation where it matters most.

This is a great opportunity for a principal level mechanical engineer to join a high-performing enigneering team who brings technical experience and a fresh perspective to complex design challenges. You will play a hands‑on role in designing, analyzing, and testing rugged subsystems and complex PCB assemblies that are core to Mercury's high‑performance product portfolio. The ideal candidate thrives in a fast‑paced, multidisciplinary environment and is driven to translate innovative ideas into impactful, mission‑ready solutions.

Job Responsibilities:

• Lead products through the full lifecycle; from concept development to integration, testing, and production release.
• Perform mechanical engineering activities for rugged subsystems and complex PCB assemblies, including mechanical packaging, connector selection, cable and label design, prototype inspection and assembly, environmental testing, and supporting hardware documentation procurement
• Collaborate closely with cross‑functional partners such as Hardware/Electrical Engineering, Manufacturing, Quality Engineering, and Procurement
• Develop and maintain Bills of Material (BOMs/PLs) to support accurate configuration and production control
• Draft, submit, and manage Engineering Change Requests (ECRs) and Engineering Change Orders (ECOs)
• Conceptualize, design, analyze, and document mechanical hardware and systems intended for rugged military and space environments
• Conduct thermal and structural analysis and/or simulations to ensure robust mechanical and environmental performance
• Design complex fixtures to support product testing and advanced manufacturing processes
• Create detailed 3D models and engineering drawings
• Communicate design concepts and produce clear, high‑quality product documentation for diverse internal and external audiences
• Support environmental and functional design verification testing in accordance with MIL‑STD‑810 for severe operating conditions
• Provide hands‑on support during initial build validation of new designs, ensuring form, fit, and function are met
• Perform failure analysis of discrepant material in partnership with Manufacturing and Quality Engineering teams
• Develop test plans, inspection reports, and associated documentation in support of verification and validation activities
• Mentor and train junior engineers

Required Qualifications:

• Bachelor''s degree in mechanical or aerospace engineering
• Typically requires a minimum of 6 years of relevant mechanical engineering experience
• Familiarity with GD&T, ASME Y14.5, Y14.100
• Experience and understanding of PWA/CCA design and associated manufacturing processes
• Proven experience designing electronics packaging for severe environments, including compliance with MIL‑STD‑810
• Proficiency with 3D CAD software such as SolidWorks or CREO
• Broad knowledge of both conventional and advanced manufacturing techniques, including machining and post‑processing for CCAs and metal components
• Strong foundational understanding of heat‑transfer design principles and dynamic system design for shock and random vibration environments
• Familiarity with configuration management and material control processes, including routers, work instructions, and related tools i.e. Agile, Oracle, EPDM

Proficiency with standard engineering documentation and presentation tools

• This role requires the ability to obtain and maintain a U.S. government security clearance; U.S. citizenship is required

Preferred Qualifications:

• Master''s degree in mechanical or aerospace engineering
• Aerospace and Defense Industry experience
• Expertise with GD&T, ASME Y14.5, Y14.100
• Experience performing thermal analysis using tools such as 6Sigma, Celsius, SC Stream, or SC Flow
• Experience performing Structural analysis using tools such as SolidWorks Simulation, Femap/NASTRAN)