Senior Mechanical Engineer, CHAOS Industries

• The ideal candidate has strong hands-on mechanical CAD experience, a solid understanding of ruggedized electronics packaging design, and the ability to work independently while collaborating closely with electrical, RF, and systems engineers
• Bachelor’s degree in Mechanical Engineering or a related discipline
• 4+ years Relevant experience in mechanical design and integration of electronic hardware for aerospace, defense, or similar applications
• Strong proficiency with mechanical CAD tools (e.g., SolidWorks or equivalent) and experience producing production-ready drawings
• Experience designing mechanical hardware for RF, avionics, power electronics, and/or embedded computing products
• Solid understanding of mechanical drafting standards, GD&T, tolerance analysis, and configuration-controlled documentation
• Experience supporting prototype builds, integration, and qualification testing
• Strong problem-solving skills, attention to detail, and ability to work effectively in fast-paced development programs
• Ability to obtain and maintain a U.S. security clearance

Desirable

• CHAOS is seeking a Senior Mechanical Design Engineer to support the design, integration, and qualification of electronic hardware and enclosures for aerospace and defense applications
• In this role, you will be a key contributor responsible for the detailed mechanical design of electronic subsystems
• The position spans the full product lifecycle, from early concept development and architecture through detailed design, analysis, prototyping, qualification testing, production, and sustainment of fielded systems
• Design ruggedized electronic hardware and enclosures, including chassis, card-level packaging, mounting features, and thermal solutions, in accordance with program requirements and applicable standards
• Develop and maintain 3D CAD models, assemblies, and interface control documentation (ICDs) to support multi-disciplinary system integration
• Track and manage size, weight, and mechanical allocations for electronic assemblies
• Perform first-order structural and thermal analyses to support design decisions and verify compliance with environmental and performance requirements
• Support and prototype hardware fabrication, mechanical integration, testing, and field validation activities
• Participate in design reviews, qualification efforts, and failure investigations
• Collaborate with cross-functional teams to ensure mechanical designs integrate cleanly within larger systems
• Interface with suppliers, vendors, and manufacturing partners to support component selection, fabrication, and assembly
• Support production transition, Design for Manufacturing and Assembly (DFMA) efforts, configuration control, and sustainment of fielded hardware