Principal Mechanical Engineer

Job Summary:

Mercury Systems is seeking the best and brightest engineering talent to help us deliver cutting‑edge technology for mission‑critical aerospace and defense applications, advancing innovation where it matters most.

This is a great opportunity for a principal level mechanical engineer to join a high-performing enigneering team who brings technical experience and a fresh perspective to complex design challenges. You will play a hands‑on role in designing, analyzing, and testing rugged subsystems and complex PCB assemblies that are core to Mercury’s high‑performance product portfolio. The ideal candidate thrives in a fast‑paced, multidisciplinary environment and is driven to translate innovative ideas into impactful, mission‑ready solutions.

Job Responsibilities:

Lead products through the full lifecycle; from concept development to integration, testing, and production release.

Perform mechanical engineering activities for rugged subsystems and complex PCB assemblies, including mechanical packaging, connector selection, cable and label design, prototype inspection and assembly, environmental testing, and supporting hardware documentation procurement

Collaborate closely with cross‑functional partners such as Hardware/Electrical Engineering, Manufacturing, Quality Engineering, and Procurement

Develop and maintain Bills of Material (BOMs/PLs) to support accurate configuration and production control

Draft, submit, and manage Engineering Change Requests (ECRs) and Engineering Change Orders (ECOs)

Conceptualize, design, analyze, and document mechanical hardware and systems intended for rugged military and space environments

Conduct thermal and structural analysis and/or simulations to ensure robust mechanical and environmental performance

Design complex fixtures to support product testing and advanced manufacturing processes

Create detailed 3D models and engineering drawings

Communicate design concepts and produce clear, high‑quality product documentation for diverse internal and external audiences

Support environmental and functional design verification testing in accordance with MIL‑STD‑810 for severe operating conditions

Provide hands‑on support during initial build validation of new designs, ensuring form, fit, and function are met

Perform failure analysis of discrepant material in partnership with Manufacturing and Quality Engineering teams

Develop test plans, inspection reports, and associated documentation in support of verification and validation activities

Mentor and train junior engineers

Required Qualifications:

Bachelor's degree in mechanical or aerospace engineering

Typically requires a minimum of 6 years of relevant mechanical engineering experience

Familiarity with GD&T, ASME Y14.5, Y14.100

Experience and understanding of PWA/CCA design and associated manufacturing processes

Proven experience designing electronics packaging for severe environments, including compliance with MIL‑STD‑810

Proficiency with 3D CAD software such as SolidWorks or CREO

Broad knowledge of both conventional and advanced manufacturing techniques, including machining and post‑processing for CCAs and metal components

Strong foundational understanding of heat‑transfer design principles and dynamic system design for shock and random vibration environments

Familiarity with configuration management and material control processes, including routers, work instructions, and related tools i.e. Agile, Oracle, EPDM Proficiency with standard engineering documentation and presentation tools

This role requires the ability to obtain and maintain a U.S. government security clearance; U.S. citizenship is required

Preferred Qualifications:

Master's degree in mechanical or aerospace engineering

Aerospace and Defense Industry experience

Expertise with GD&T, ASME Y14.5, Y14.100

Experience performing thermal analysis using tools such as 6Sigma, Celsius, SC Stream, or SC Flow

Experience performing Structural analysis using tools such as SolidWorks Simulation, Femap/NASTRAN)