Senior Principal Mechanical Engineer, CHAOS Industries

• Bachelor’s degree in Mechanical Engineering or a related discipline
• 12+ years of progressively responsible experience in mechanical design and integration of electronic hardware for aerospace, defense, or similar applications
• Expert proficiency with mechanical CAD tools (e.g., SolidWorks or equivalent) and experience producing production-ready drawings
• Expertise in mechanical interfaces, tolerancing, alignment, installation practices, and interface control documents (ICDs)
• Familiarity with military and aerospace connectors (e.g., MIL-DTL-38999, ARINC, Micro-D)
• Strong understanding of mechanical drafting standards, GD&T, tolerance analysis, and configuration-controlled documentation
• Demonstrated experience with ruggedized military hardware and environmental qualification considerations
• Experience interpreting and applying military standards, such as MIL-STD-810 and related platform qualification requirements
• Proven ability to lead technical decisions and resolve complex, cross-disciplinary integration challenges
• Strong written and verbal communication skills and ability to operate effectively across multiple programs
• Ability to obtain and maintain a U.S. security clearance

Desirable

• CHAOS is seeking a Senior Principal Mechanical Design Engineer to serve as the technical authority for the design, integration, and qualification of electronic hardware and enclosures for aerospace and defense applications
• This role is responsible for setting mechanical direction across programs, solving complex design challenges, and ensuring technical excellence from concept through qualification, production, and sustainment
• The ideal candidate brings deep hands-on mechanical design expertise, strong CAD and packaging experience, and a proven ability to independently lead cross-disciplinary technical efforts spanning mechanical, electrical, RF, power, and systems engineering
• Architect and design ruggedized electronic hardware and enclosures, including chassis, card-level packaging, mounting features, and thermal solutions, in accordance with program requirements and applicable standards
• Define and maintain mechanical architectures, interfaces, and design approaches to support multi-disciplinary system integration
• Develop and oversee 3D CAD models, assemblies, drawings, and interface control documentation (ICDs), ensuring production-ready quality and configuration control
• Perform first-order structural and thermal analyses to support design decisions and verify compliance with environmental and performance requirements
• Perform and/or review first-order structural and thermal analyses to support design decisions and verify compliance with environmental and performance requirements
• Lead cross-disciplinary technical resolution involving mechanical, electrical, RF, power, and systems engineering teams
• Serve as a primary technical hardware interface with customers, platform providers, suppliers, and manufacturing partners
• Perform make/buy assessments with manufacturing partners as required
• Support production transition, configuration control, and fielded system sustainment, including investigation and resolution of integration issues