Senior Mechanical Design Engineer - Aerospace Hardware

Job Description

Job Description

Company Summary

EchoStar builds solutions that help families and communities stay connected. We’ll launch your career and empower you to change lives.

Our brands include Boost Mobile, DISH TV, Gen Mobile, Hughes and Sling TV. We serve millions of customers with offerings ranging from satellite to streaming services and global to personal networking solutions.

EchoStar has an exciting opportunity in our Hughes Network Systems division for a dynamic and experienced Senior Mechanical Design Engineer – Aerospace Hardware . This position will be located at our headquarters in Germantown, MD .

Job Duties and Responsibilities

Key Responsibilities:

• Lead end-to-end hardware development for AERO mobile solution, from conceptual design through production and in-service operation
• Interact with various stakeholders
• Own design, HW verification and qualification testing, production ramp up and field deployment
• Define design criteria, collaborate cross-functionally to refine requirements, and drive system-level optimization
• Perform engineering analyses using hand calculations, FEA, CFD, and CAD tools in a fast-paced, iterative environment
• Rapidly develop and refine design solutions to support system trade studies and influence overall product direction
• Lead design reviews and partner with internal certification team to qualify components and systems
• Develop detailed production drawings using GD&T and conduct tolerance stack-up analyses to ensure manufacturability and performance
• Drive design for manufacturability (DFM), simplifying designs, reducing part and process count, and implementing robust error-proofing strategies
• Establish and optimize the product lifecycle from supply chain through final integration, balancing cost, quality, and complexity
• Collaborate with cross-functional partners to design and implement efficient in-house production capabilities
• Plan and execute environmental and performance testing to validate designs and ensure compliance with requirements
• Own product delivery timelines across all phases—concept, design, build, and service—while driving continuous improvements in reliability and performance

Skills, Experience and Requirements

Basic Requirements:

• Bachelor's degree in mechanical engineering, aerospace engineering, or related technical field
• 6+ years of experience with mechanical/electromechanical design, analysis, testing, and/or manufacturing

Preferred Qualifications:

• Strong foundation in mechanical engineering principles, including statics, dynamics, thermodynamics, and materials
• Proven experience in hardware design and development for complex systems, preferably in aerospace or similar high-reliability environments
• Proficiency in CAD tools (e.g., Creo, Solidworks etc.) and engineering analysis methods including FEA and CFD (e.g. Flotherm, FloEFD etc.)
• Experience performing hand calculations and validating designs through analytical and simulation approaches
• Experience with electronic board assembly design, including mechanical integration, mounting strategies, and thermal management solutions
• Working knowledge of electronics design across chip-level, package-level, and board-level integration
• Deep understanding of GD&T and tolerance stack-up analysis for production-ready designs
• Knowledge of design for manufacturability (DFM) and design for assembly (DFA) principles
• Familiarity with FAA certification processes and working with regulatory standards (e.g., DO-160, FARs)
• Experience conducting environmental and performance testing, including validation and verification methods
• Strong problem-solving skills with the ability to work effectively in fast-paced, iterative development environments
• Excellent communication and collaboration skills, with experience working across multidisciplinary teams (electrical, RF, EMC, manufacturing)
• Ability to manage multiple priorities and own product development timelines from concept through production
• Strong attention to detail, with a focus on reliability, performance, and continuous improvement
• Experience with aircraft systems or avionics hardware integration
• Familiarity with RF, EMI/EMC considerations in hardware design
• Experience supporting high-rate production environments or in-house manufacturing lines
• Knowledge of supply chain, production processes, and lifecycle management
• Advanced degree in Mechanical Engineering or related field

Visa sponsorship not available for this position

Benefits

We offer versatile health perks, including flexible spending accounts, HSA, a 401(k) Plan with company match, ESPP, career opportunities, and a flexible time away plan; all benefits can be viewed here: EchoStar Benefits.

The base pay range shown is a guideline. Individual total compensation will vary based on factors such as qualifications, skill level, and competencies; compensation is based on the role's location and is subject to change based on work location.

Candidates need to successfully complete a pre-employment screen, which may include a drug test and DMV check. Our company is committed to fostering an inclusive and equitable workplace where every individual has the opportunity to succeed. We are dedicated to providing individuals with criminal or arrest records a fair chance of employment in accordance with local, state, and federal laws.

The posting will be active for a minimum of 3 days. The active posting will continue to extend by 3 days until the position is filled.

We pride ourselves on developing and promoting talent as an Equal Employment Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, disability, or protected veteran status. EchoStar will accommodate the sincerely held religious beliefs of employees if such accommodations are not undue hardships and are otherwise within the bounds of applicable law. All qualified applicants with arrest or conviction records will be considered for employment in accordance with local, state, and federal law. You may redact any information that identifies age, date of birth, or dates of school/graduation from your application documents before submission and throughout our application process.

EchoStar will provide reasonable accommodation to otherwise qualified job applicants and employees with known physical or mental disabilities, unless doing so poses an undue hardship on the Company, poses a direct threat of substantial harm to others, or is otherwise not required by law. EchoStar has a more detailed Accommodation Policy that applies to employees. EchoStar endeavors to make echostar.com and jobs.echostar.com accessible to users. Please contact View email address on ziprecruiter.com if you would like to discuss the accessibility of our website or need assistance completing the application process. This contact information is for accommodation requests only; do not use this contact information to inquire about the status of applications.

Click the links to access the following statements: EEO Policy Statement, Pay Transparency, EEOC Know Your Rights (English/Spanish)