Mechanical Designer

Mechanical Design EngineerThis role seeks a highly motivated and skilled Mechanical Design Engineer to support customers in Washington, DC. You will serve as a hands-on engineer with a strong experience in mechanical systems, equipment, assemblies, and product development. The position involves full-lifecycle engineering, from concept development and design to prototyping, testing, integration, maintenance, and sustainment of advanced systems and hardware for communication systems. You will work onsite alongside other engineers and professionals at various customer locations, collaborating with multi-disciplinary teams in a fast-paced and challenging environment.ResponsibilitiesDesign and develop robust and reliable mechanical and electromechanical systems, assemblies, and components for advanced communication systems.Analyze system requirements and translate them into detailed mechanical design specifications.Create 3D CAD models, engineering drawings, and manufacturing documentation using industry-standard tools.Perform tolerance analysis, material selection, and design-for-manufacturability (DFM) assessments to ensure high-quality, producible designs.Create and maintain detailed documentation for all stages of the design process, from concept through sustainment.Develop and execute comprehensive test plans for mechanical systems and assemblies to validate performance and reliability.Build, assemble, and evaluate prototypes to confirm design intent and performance requirements.Identify, troubleshoot, and resolve mechanical and system-level issues in a timely manner, including urgent and high-priority scenarios.Perform root cause analysis of failures and implement effective corrective actions.Support environmental, vibration, thermal, and functional testing activities to qualify systems and components.Integrate new mechanical systems and components into existing platforms and infrastructure.Support fabrication, assembly, installation, and maintenance activities for deployed systems.Coordinate with manufacturing teams, technicians, engineers, and suppliers to ensure successful hardware implementation.Perform routine maintenance, upgrades, and configuration improvements on mechanical and electromechanical equipment for communications equipment and antenna systems.Work closely with a small, highly effective team to understand customer needs and provide responsive technical support.Collaborate with multi-disciplinary engineering teams to ensure project success and alignment with technical requirements.Communicate project status, design decisions, and technical information clearly and effectively to peers and stakeholders.Use hand tools, power tools, precision measurement equipment, and shop equipment safely and effectively while executing design, build, and test activities.Maintain a proactive, self-directed approach to problem-solving in a high-stress, high-speed environment while meeting project deadlines.Essential SkillsBachelor's degree in Mechanical Engineering, Aerospace Engineering, Manufacturing/Industrial Engineering, or a related technical field, or equivalent work experience.5–10+ years of proven experience in mechanical design and product development.Strong experience with full-lifecycle engineering, including concept development, design, prototyping, testing, integration, manufacturing support, and sustainment.Proficiency with SolidWorks 3D CAD/CAM software.Experience creating technical drawings, specifications, documentation, and design analyses.Hands-on experience with fabrication, assembly, testing, and troubleshooting of complex mechanical systems.Strong understanding of materials, machining processes, fasteners, tolerance stack-ups, and manufacturing methods such as additive manufacturing/3D printing, CNC machining, and injection molding.Experience working with hand tools, power tools, precision measurement equipment, and shop equipment.Excellent interpersonal and communication skills, with the ability to interact effectively with customers and peers.Demonstrated ability to work effectively in a high-stress, high-speed environment while maintaining quality and accuracy.Ability to work both independently and collaboratively within a multi-disciplinary team.Strong initiative, self-motivation, and a proactive approach to problem-solving without requiring constant direction.Active DoD Secret clearance with the ability to obtain and maintain a DoD TS/SCI clearance.Ability to lift and/or move up to 50 pounds as part of routine duties.Additional Skills & QualificationsExperience supporting mechanical systems and hardware for communication systems and antenna platforms.Experience in electromechanical systems design and integration.Familiarity with design-for-manufacturability (DFM) and design-for-assembly (DFA) principles in a production environment.Experience coordinating with suppliers and manufacturing partners to implement mechanical designs.Comfort working with legacy systems as well as new and emerging technologies.Ability to clearly document design decisions, test results, and configuration changes for long-term sustainment.Work EnvironmentThis position is fully onsite at a customer facility in Washington, DC, with primary work taking place at a laboratory and engineering environment. Typical shifts are early, such as 6:30 a.m. to 2:30 p.m. or 3:00 p.m. to 7:00 p.m., depending on project needs. You will work closely with other engineers, technicians, and professionals in a fast-paced, hands-on setting that involves frequent use of advanced equipment, tools, and technologies to support both legacy and new mechanical systems. The role includes time in engineering offices for design and documentation as well as shop and lab spaces for fabrication, assembly, integration, and testing. You will handle mechanical components and equipment, operate hand and power tools, and use precision measurement instruments and shop equipment while adhering to appropriate safety practices and attire for a technical lab and shop environment. Actalent