Principal Mechanical Engineer

Job Description
BAE Systems is seeking a Principal Mechanical Engineer to join our team in Austin, Texas!


"We Protect Those Who Protect Us®" is our mission, and we're looking for engineers who share our passion in developing a full range of first-of-its-kind technologies and equipment to protect air, land, and naval warfighters on all fronts. At our Austin, Texas site, the Countermeasure & Electromagnetic Attack Solutions team provides next-generation threat detection and countermeasure solutions that provide unparalleled electronic warfare capabilities to enhance mission survivability.


If you are an individual who thrives in Agile hardware development environments, then we are interested in hearing from you! This exciting role spans the full product lifecycle - business capture, development, production, testing, sustaining - for a variety of complex defense products and technologies. You will collaborate closely with other electrical, mechanical, software, firmware and test engineers, as well as product managers and stakeholders to develop excellent solutions.


We are looking for candidates who are detail-oriented, possess strong analytical skills, and have a passion for continuous improvement. You will be responsible for ensuring the performance, quality, and reliability of electronic products through rigorous design, analysis, and testing. In addition, the ideal candidate has experience with, and is a strong advocate of, Agile hardware development, risk-reduction prototyping, and requirements-driven design and verification.


Typical duties assigned to this position:

• 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 assure fit & function
• Perform 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 that adhere to DTUPC, DFT, and DFM requirements
• Support resolution of technical issues discovered during manufacture and test of deliverable hardware
• Evaluate and troubleshoot mechanical faults and issues, assessing test failures for root cause, identifying disposition/corrective actions
• Design test equipment to ensure the performance and integrity of manufactured products
• Participate in requirements development, performing technical trade studies, and evaluating technology insertion/upgrades
• Develop and execute test plans, which includes the integration of test solutions, and provide detailed reports on test results
• Participate in new business capture

Current BAE Systems employees are ineligible for sign-on bonuses.

Required Education, Experience, & Skills

• Bachelor's degree in Mechanical Engineering
• 6+ years (or 4+ years with MS ME) designing, testing, and troubleshooting high-reliability embedded systems
• Demonstrated understanding of mechanical principles, test methodologies, and the ability to work with advanced test equipment and cutting-edge technology
• Strong "hands-on" laboratory experience with instrumentation, equipment, and processes
• Eligible to obtain a DOD Security Clearance

Preferred Education, Experience, & Skills

• Possess an understanding in the application of heat transfer principles, strength of materials, materials selection, design for vibration environments and the ability to apply those principles to unique mechanical design challenges
• Experience with mechanical engineering tools for design and analysis, including ANSYS Workbench/Mechanical, PTC Creo, MATLAB/Simulink, Siemens NX, ANSYS Icepak
• Familiarity with design, analysis, and manufacturing standards associated with complex multilayer rigid and rigid-flex CCAs
• Knowledge of engineering development processes for aero/defense industry, including designing and testing to ASTM, SAE, DO, MIL-STD-810
• A self-starter with Agile hardware development experience
• Exceptional degree of ingenuity, creativity and resourcefulness
• Control account management experience
• Experience with LRIP / FRP, especially electronics manufacturing and test methodologies
• Familiarity with AS9145 compliant processes
• Strong written and verbal communication skills
• Active DOD security clearance

Pay Information
Full-Time Salary Range: $115779 - $196825

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


Employee Benefits: At BAE Systems, we support our employees in all aspects of their life, including their health and financial well-being. Regular employees scheduled to work 20+ hours per week are offered: health, dental, and vision insurance; health savings accounts; a 401(k) savings plan; disability coverage; and life and accident insurance. We also have an employee assistance program, a legal plan, and other perks including discounts on things like home, auto, and pet insurance. Our leave programs include paid time off, paid holidays, as well as other types of leave, including paid parental, military, bereavement, and any applicable federal and state sick leave. Employees may participate in the company recognition program to receive monetary or non-monetary recognition awards. Other incentives may be available based on position level and/or job specifics.

About BAE Systems Electronic Systems
BAE Systems, Inc. is a defense, aerospace, and security company headquartered in Falls Church, Virginia, with more than 40,000 employees worldwide. We serve, supply, and protect those who protect us. As one of the most geographically diverse international defense companies, we deliver a full range of products and services spanning air, land, maritime, space, and cyber, including advanced electronics, intelligence solutions, and dedicated customer support.

Our culture is performance-driven and values-led, built on curiosity, creativity, and collaboration. Purpose isn't a tagline here. It's what drives us. We're developing breakthrough technologies that defend national security and make a lasting impact on our communities and our planet. When you join BAE Systems, you're not just building a career. You're contributing to a mission that truly matters.

This position will be posted for at least 5 calendar days. The posting will remain active until the position is filled, or a qualified pool of candidates is identified.