Principal Mechanical Engineer

Principal Mechanical EngineerCHAOS Industries is redefining modern defense with omniscient systems purpose-built for today's realities. Designed and built by top U.S. military veterans and Silicon Valley innovators, CHAOS Industries' products are powered by Coherent Distributed Networks (CDN™), empowering warfighters, commercial air operators, and border protection teams to act faster, adapt rapidly, and stay ahead of evolving threats. In a world where technological threats move at unprecedented speed, CHAOS Industries delivers advanced sensing and detection solutions that give the ultimate advantage: time.Role Overview:CHAOS is seeking a Principal Mechanical Engineer to provide high-value, hands-on mechanical expertise for the integration of ruggedized electronics, effectors, and mission-critical hardware into ground- and sea-mobile platforms for aerospace and defense applications. In this role, you will own and lead the design for mechanical integration of military electronics and effector systems with critical platform structures and mechanisms. Design challenges may range from compact electronics enclosures to larger structural or mechanism assemblies, depending on platform and mission requirements.The position spans the full product lifecycle, from early concept development and architecture through detailed design, analysis, prototyping, qualification testing, production, and sustainment of fielded systems.The ideal candidate has strong hands-on mechanical CAD and system integration experience, demonstrated prototyping skills, a deep understanding of ruggedized hardware design, and a proven ability to work independently and guide cross-disciplinary engineering efforts. This is a full-time, on-site position in El Segundo, CA.Responsibilities:Provide technical leadership and hands-on prototyping and mechanical integration of mission systems: electronics, enclosures, effectors, launchers, mechanisms, and support equipment into ground- and sea-mobile platformsArchitect and design mechanical structures, frames, mounts, enclosures, and mechanisms subject to shock, vibration, thermal, and environmental constraintsDevelop and maintain 3D CAD models, assemblies, and interface control documentation (ICDs) to support multi-disciplinary system integrationPerform first-order structural and thermal analyses and requirements allocations to ensure compliance with customer requirements and applicable military standardsLead system-level integration, qualification, and acceptance activities, including oversight of installation, alignment, and fit-check effortsServe as a primary technical hardware interface with customers, platform providers, suppliers, and manufacturing partners. Perform make/buy assessmentsSupport production transition, configuration control, and fielded system sustainment, including investigation and resolution of integration issuesMinimum Requirements:Bachelor's degree in Mechanical Engineering or a related discipline8+ years of progressively responsible experience in platform-level mechanical design and system integration for aerospace and defense applicationsProven experience integrating mechanical subsystems and mission systems into vehicles, mobile platforms, or fixed installationsStrong proficiency with CAD tools (e.g., SolidWorks or equivalent) for large assemblies and top-down designSolid understanding of mechanical interfaces, tolerancing, alignment, installation practices, and interface control documents (ICDs)Familiarity with structural analysis methods (hand calculations, FEA)Familiarity with ruggedized military hardware and environmental qualification considerationsExperience interpreting and applying military standards, such as MIL-STD-810 and related platform qualification requirementsDemonstrated ability to lead technical decisions and resolve complex, cross-disciplinary integration challengesStrong communication skills and ability to operate effectively in multi-project development environmentsAbility to obtain and maintain a U.S. security clearancePreferred Requirements:Master's degree in Mechanical Engineering or a related fieldPrior experience serving as a mechanical technical authority on a programExperience with mechanisms and actuation systems, including linkages, bearings, motors, hydraulics, and pneumatics, gimbals, or rotary jointsExperience with system-level requirements allocationFamiliarity with vehicle integration constraints, including shock, vibration, transport, and operational loadsExperience with at least one commercial FEA or multiphysics simulation package (NASTRAN, ABAQUS, ANSYS, CFD codes, COMSOL, etc.)Knowledge of manufacturing and assembly processes for mobile or deployable mechanical structures and mechanismsExperience with prototyping, additive manufacturing, CNC machining, and other fabrication techniquesFamiliarity with military-style connectors (e.g., mil-circular 38999, ARINC, micro-D)Why CHAOS?Health Benefits: Medical, dental, and vision benefits 100% paid for by the companyAdditional benefits: 401k (+ 50% company match up to 6% of pay), FSA, HSA, life insurance, and moreOur Perks: Free daily lunch, 'No meeting Fridays', unlimited PTO, casual dress codeCompensation Components: Competitive base salaries, generous pre-IPO stock option grants, relocation assistance, and (coming soon!) annual bonusesTeam Growth: 200 employees and counting across 5 global offices$175k-215kThe stated compensation range reflects only the targeted base compensation range and excludes additional earnings such as bonus, equity, and benefits. If your compensation requirements fall outside of the range, we still encourage you to apply. The salary range for this role is an estimate based on a range of compensation factors, inclusive of base salary only. Actual salary offer may vary based on (but not limited to) work experience, education and/or training, critical skills, and/or business considerations.