Principal Mechanical Engineer

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.

In this role, our team is looking for an experienced, motivated engineer eager to make a meaningful impact from day one. As a principal mechanical engineer, you will take a hands‑on role in designing, analyzing, and testing complex electronics subsystems that directly support mission‑critical product development. You will bring fresh thinking and technical leadership to challenging design problems, helping drive continuous improvement and engineering excellence. Working in a collaborative, fast‑paced environment, you’ll play a significant part in shaping reliable, cutting‑edge technology that aligns with the company’s commitment to innovation, quality, and customer success.

Job Responsibilities:

Design and develop electronic module assemblies using open standards, including mechanical packaging, printed wiring board layouts, ECAD support, connector selection, cable and label design, prototype inspection, and environmental testing

Perform mechanical packaging tasks for electronics integrated within larger subsystems, including backplane and cable design

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

Lead products from concept through design, integration, testing, and final production release

Conceptualize, design, develop, and analyze mechanical hardware and systems for rugged military applications, including thermal, structural, reliability, materials, and tolerance analyses

Design complex fixtures to support testing and advanced manufacturing processes

Create detailed 3D models and engineering drawings using SolidWorks

Conduct peer reviews of designs, analyses, and engineering documentation

Communicate and present technical concepts and product documentation to diverse internal and external audiences

Support product verification testing, including thermal, airflow, vibration, mechanical shock, humidity, and environmental stress screening

Coordinate procurement of prototype materials and validate form, fit, and function

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

Develop test plans, inspection reports, and documentation for verification and validation activities

Create and maintain Bills of Material (BOMs/PLs)

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

Support sustaining engineering and legacy product efforts

Required Qualifications:

Bachelor’s degree in mechanical engineering, aerospace engineering, or a related technical discipline

Typically requires a minimum of 6+ years of related industry experience

Strong experience in electronics packaging, design, and processes

Solid understanding of structural dynamics, heat transfer, and thermal management of electronics

Knowledge of conventional manufacturing methods and advanced manufacturing, including additive manufacturing

Proficiency with 3D CAD software, preferably SolidWorks

Familiarity with material control processes and documentation, including routers and work instructions, as well as related systems i.e. Agile, Oracle, EPDM

This position is onsite in Andover, MA or Hudson, NH.

“This position requires you to access information that is subject to U.S. export regulations. You may only access such information if you are a U.S. citizen, lawful permanent resident of the U.S., protected individual as defined by 8 U.S.C. 1324b(a)(3), or eligible to obtain the required authorizations from the U.S. government.”

Preferred Qualifications:

Master's degree in mechanical or aerospace engineering or a related technical discipline

10+ years' experience

Familiarity with RF Engineering practices

Strong proficiency with GD&T and tolerance analysis

Proficient in SolidWorks

Experience conducting thermal analysis using tools such as 6Sigma or Celsius

Experience with structural analysis using tools such as SolidWorks Simulation, Femap/NASTRAN

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