Senior Mechanical Engineer

Sr Mechanical Engineer

Job Description

This Sr Mechanical Engineer role leads the development of innovative, complex electromechanical systems from initial concept through full production implementation. The position spans early system concept of operations (CONOPS), detailed mechanical design, rigorous analysis, comprehensive design reviews, and oversight of testing and validation for high-reliability, mission-critical mechanisms and electromechanical systems.

Responsibilities

• Lead the mechanical design and development of complex, high-reliability electromechanical systems from concept through production implementation.
• Participate in early systems CONOPS activities and translate operational concepts into clear mechanical and system requirements.
• Drive mechanical efforts through a structured, multi-stage design review process, including managing several periodic review gates and presenting technical content.
• Design mechanical systems and mechanisms in 3D CAD, creating complete system models from concept to detailed design.
• Use PLM/PDMS systems to manage design data, documentation, and configuration control throughout the product lifecycle.
• Analyze mechanical models and systems using computer-based finite element analysis (FEA), supported by hand calculations to validate results and ensure robustness.
• Lead requirements definition, traceability, and compliance activities, ensuring that mechanical designs meet system-level requirements.
• Plan and execute verification and validation activities for mechanical systems, including creation and maintenance of requirements verification matrices.
• Prepare and maintain comprehensive technical documentation, including system design descriptions, CONOPS documents, and interface control documents (ICDs).
• Create and maintain risk management plans, identifying technical risks and mitigation strategies for mechanical designs.
• Help develop test plans and test cases for mechanical and electromechanical systems, including environmental and functional testing.
• Manage products through test campaigns, incorporating feedback from quality and other teams to refine designs and resolve issues.
• Collaborate closely with multidisciplinary teams to ensure effective communication across system interfaces and alignment with end-user needs.
• Own development schedules and project milestone reviews, tracking progress and ensuring mechanical deliverables meet program timelines.
• Organize and run technical interchange meetings to coordinate design decisions, resolve technical issues, and align stakeholders.
• Mentor other engineers, providing technical guidance, design review feedback, and support in developing their skills and capabilities.
• Support business development activities, including contributing to proposals and providing technical input on new opportunities.
• Contribute to continuous improvement of mechanical design, analysis, and documentation practices within the engineering organization.

Essential Skills

• Bachelors degree in Mechanical Engineering.
• Approximately 58 years of relevant professional mechanical engineering experience, with sufficient depth to confidently lead complex development efforts.
• At least 23 years of lead or technical responsibility over hardware development efforts, demonstrating ownership of design, analysis, and delivery.
• Proficiency in 3D CAD software for complete system design from concept through detailed design; experience with NX is preferred, but other CAD packages are acceptable.
• Strong mechanical leadership and technical design capabilities to serve as lead mechanical engineer on complex, high-reliability products.
• Experience designing mechanical systems and mechanisms, including mission-critical, high-reliability electromechanical systems.
• Knowledge of finite element analysis (FEA) principles, with hands-on experience performing mechanical FEA strongly preferred.
• Experience using PLM/PDMS systems for document and configuration management; Siemens-based systems are ideal, though other platforms are acceptable.
• Ability to perform and interpret hand calculations to support and validate analytical and FEA results.
• Experience with mechanical testing activities and working with test teams during development and qualification.

Additional Skills & Qualifications

• Experience performing FEA analysis using NASTRAN/FEMAP is preferred; experience with other FEA software tools is also valuable.
• Familiarity with spacecraft environmental testing systems, such as thermal vacuum, vibration, and acoustic testing, is highly desirable.
• Experience with high-reliability deployment and motion hardware such as hold-down and release mechanisms (HDRM), docking systems, rotary hinges, solar arrays, drive assemblies, and electric motors is a strong plus.
• Experience working with a variety of structural and mechanical materials, including aluminum, stainless steel, titanium, exotic alloys, and carbon fiber composites.
• Knowledge of various surface treatments and processes, such as anodizing, electrolytic nickel plating, hardening, heat treatments, and precision surface finishing.
• Systems engineering experience, including requirements management, interface definition, and verification planning.
• Demonstrated ability to work to tight deadlines and manage engineering tasks to meet project milestones.
• Strong communication skills with the ability to collaborate effectively across multidisciplinary teams and present technical information clearly.
• Interest in growing into broader technical leadership roles within a dynamic, growth-oriented commercial space environment.

Work Environment

This role is based in an office environment, working closely with multidisciplinary engineering, quality, and program teams. Work is primarily performed using 3D CAD tools, FEA software, and PLM/PDMS systems on standard engineering workstations. The position involves regular participation in design reviews, technical interchange meetings, and collaborative sessions with other engineers and stakeholders. Typical working hours follow standard office schedules, with flexibility required at times to meet critical project deadlines and milestone reviews. The environment supports professional growth into greater leadership responsibilities within a fast-paced, innovative commercial space-focused organization, with a culture that values technical excellence, collaboration, and ownership of resul

This is a Contract to Hire position based out of Silver Spring, MD.

The pay range for this position is $55.00 - $80.00/hr.

Individual compensation offered for this position within this range will depend on many factors, including qualifications, skills, relevant experience, job knowledge, geographic location, internal equity, and other pertinent job-related factors.

Eligibility requirements apply to some benefits and may depend on your job classification and length of employment. Benefits are subject to change and may be subject to specific elections, plan, or program terms. If eligible, the benefits available for this temporary role may include the following: Medical, dental & vision Critical Illness, Accident, and Hospital 401(k) Retirement Plan Pre-tax and Roth post-tax contributions available Life Insurance (Voluntary Life & AD&D for the employee and dependents) Short and long-term disability Health Spending Account (HSA) Transportation benefits Employee Assistance Program Time Off/Leave (PTO, Vacation or Sick Leave)

This is a Contract to Hire position based out of Silver Spring, MD.

This position is anticipated to close on Nov 6, 2026.

This is a fully onsite position in Silver Spring,MD.

About Actalent

Actalent is a global leader in engineering and sciences services and talent solutions. We help visionary companies advance their engineering and science initiatives through access to specialized experts who drive scale, innovation and speed to market. With a network of almost 20,000 consultants and 5,000 clients across the U.S., Canada, Asia and Europe, Actalent serves many of the Fortune 500. We are proud to be an Engineering News-Record (ENR) Top 500 Design Firm for our engineering design services and a ClearlyRated Best of Staffing® winner for both client and talent service.

The company is an equal opportunity employer and will consider all applications without regard to race, sex, age, color, religion, national origin, veteran status, disability, sexual orientation, gender identity, genetic information or any characteristic protected by law.

If you would like to request a reasonable accommodation, such as the modification or adjustment of the job application process or interviewing process due to a disability, please email View email address on click.appcast.io for other accommodation options.

San Francisco Fair Chance Ordinance: Pursuant to the San Francisco Fair Chance Ordinance, for all positions located in the city and county of San Francisco, we will consider for employment qualified applicants with arrest and conviction records.

Massachusetts Lie Detector: It is unlawful in Massachusetts to require or administer a lie detector test as a condition of employment or continued employment. An employer who violates this law shall be subject to criminal penalties and civil liability.

Use of Artificial Intelligence (AI): We may use Artificial Intelligence (AI) to support parts of our hiring process, including sourcing, screening, and evaluating candidates. AI helps assess applications and qualifications, but final decisions are made by our hiring team. By applying, you acknowledge and agree that your application may be reviewed using AI tools.