Mechanical Design Engineer

TSC is seeking a highly motivated and skilled Mechanical Design Engineer to support our customer in Washington, DC. The role involves full‑lifecycle engineering, from concept development and design to prototyping, testing, integration, maintenance and sustainment of advanced communication systems.

Responsibilities

Mechanical System Design & Development:

• Design and develop robust and reliable mechanical and electromechanical systems, assemblies, and components.
• Analyze system requirements and translate them into detailed mechanical design specifications.
• Create 3D CAD models, engineering drawings, and manufacturing documentation.
• Perform tolerance analysis, material selection, and design‑for‑manufacturability (DFM) assessments.
• Create and maintain detailed documentation for all stages of the design process.

Prototyping, Testing & Troubleshooting:

• Develop and execute comprehensive test plans for mechanical systems and assemblies.
• Build, assemble, and evaluate prototypes to validate designs and performance requirements.
• Identify, troubleshoot and resolve mechanical and system‑level issues in a timely manner.
• Perform root cause analysis of failures and implement corrective actions.
• Support environmental, vibration, thermal and functional testing activities.

Integration & Sustainment:

• Integrate new mechanical systems and components into existing platforms and infrastructure.
• Support fabrication, assembly, installation, and maintenance activities for deployed systems.
• Coordinate with manufacturing, technicians, engineers, and suppliers to ensure successful hardware implementation.
• Perform routine maintenance, upgrades, and configuration improvements on mechanical and electromechanical equipment.

Customer & Team Interaction:

• Work closely with a small, highly effective team to support customers in understanding their needs and providing technical support.
• Collaborate with multi‑disciplinary engineering teams to ensure project success.
• Communicate project status and technical information effectively to peers and leadership.

Required Qualifications

• Bachelor'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 (concept development, design, prototyping, testing, integration, manufacturing support, and sustainment).
• Proficiency with SolidWorks 3D CAD/CAM software and technical drawings, specifications, documentation, and design analyses.
• Hands‑on experience with fabrication, assembly, testing, and troubleshooting complex mechanical systems.
• Strong understanding of materials, machining processes, fasteners, tolerance stack‑ups and manufacturing methods (additive manufacturing, CNC machining, injection molding, etc.).
• Experience with hand tools, power tools, precision measurement equipment and shop equipment.
• Excellent interpersonal and communication skills; able to interact effectively with customers and peers.
• Demonstrated ability to work effectively in a high‑stress, high‑speed environment.
• Ability to work both independently and collaboratively within a multi‑disciplinary team.
• Strong initiative, self‑motivation, and proactive 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 50 pounds.

Clearance, Citizenship & Physical Requirements

U.S. citizenship required. Eligibility to obtain a DoD security clearance (TS/SCI). Ability to lift/move 50 lbs.

Travel & Relocation Assistance

Travel: Some (local). Relocation assistance: No.

Benefits & Compensation

Salary range: $112,000 – $190,000 per year (based on experience and location). Eligible for annual performance bonus and may include equity or incentive compensation.

Benefit package includes ESOP participation, 401(k) plan, flexible work schedules, tuition reimbursement, co‑sponsored health plan, paid leave, and more.

Equal Employment Opportunity Statement

These regulations prohibit discrimination against qualified individuals based on their status as protected veterans or individuals with disabilities, and prohibit discrimination against all individuals based on race, color, religion, sex, sexual orientation, gender identity, national origin, or discussing compensation. Moreover, these regulations require that covered prime contractors and subcontractors take affirmative action to employ and advance individuals without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, disability or veteran status. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, disability or status as a protected veteran.