Mechanical Design Engineer (Herndon)

About this Position:

This is a hands-on, individual contributor Mechanical Engineer role focused on the design and productization of subsystems for a high-altitude autonomous aerial platform used in U.S. defense programs. You will own a defined subsystem and drive it from its current prototype stage through to a rugged, field-ready, producible design. Working closely with electrical, aero, and software teams, you will design, analyze, prototype, and test hardware that operates in the stratosphere, then see it through to production handoff. The role is in person in Herndon, VA, with up to 25% travel to customer sites and field test locations.

Job Responsibilities:

• Own the mechanical design of an assigned high-altitude subsystem, translating product requirements into working hardware and maturing existing prototypes
• Perform structural, thermal, and vibration FEA to ensure designs withstand extreme temperatures and dynamic flight loads
• Design for reliability, manufacturability, and cost at the subsystem level
• Rapidly iterate through CAD, in-house 3D printing, and physical prototyping
• Plan and run bench and field tests using thermal/vacuum chambers and strain gauges to validate performance across altitude and environmental conditions
• Integrate subsystems with electrical, aero, and software teams, including avionics packaging, actuation, control, and sensor feedback interfaces
• Support flight test instrumentation setup, post-flight data analysis, and root-cause investigation of anomalies
• Apply tolerance stack-up analysis and GD&T to ensure consistent, reliable assembly
• Identify and resolve manufacturing, sourcing, and reliability issues ahead of production
• Support production handoff, working with machinists and external vendors
• Maintain models, drawings, BOMs, and design documentation, and contribute to design reviews and peer reviews
• Conduct trade studies and document lessons learned from failures

Experience Required:

• Bachelor's degree in Mechanical Engineering, Aerospace Engineering, or a related field
• 3 to 6 years of industry experience in mechanical design, ideally including high-altitude, pneumatic/fluidic, or release/deployment mechanisms
• Proficiency in SolidWorks or OnShape, with a portfolio of designs taken from concept through to hardware
• Hands-on prototyping and testing experience
• Working knowledge of FEA, GD&T, tolerance analysis, and DFM
• Ability to work in austere field conditions and support changing operational schedules
• U.S. citizenship with the ability to obtain and maintain a security clearance
• Desirable: experience in aerospace, defense, or other high-reliability industries
• Desirable: exposure to embedded systems or sensor integration, and familiarity with relevant military standards
• Desirable: startup or small-company experience