Mechanical Design Engineer

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 prototypesPerform structural, thermal, and vibration FEA to ensure designs withstand extreme temperatures and dynamic flight loadsDesign for reliability, manufacturability, and cost at the subsystem levelRapidly iterate through CAD, in-house 3D printing, and physical prototypingPlan and run bench and field tests using thermal/vacuum chambers and strain gauges to validate performance across altitude and environmental conditionsIntegrate subsystems with electrical, aero, and software teams, including avionics packaging, actuation, control, and sensor feedback interfacesSupport flight test instrumentation setup, post-flight data analysis, and root-cause investigation of anomaliesApply tolerance stack-up analysis and GD&T to ensure consistent, reliable assemblyIdentify and resolve manufacturing, sourcing, and reliability issues ahead of productionSupport production handoff, working with machinists and external vendorsMaintain models, drawings, BOMs, and design documentation, and contribute to design reviews and peer reviewsConduct trade studies and document lessons learned from failuresExperience Required:Bachelor's degree in Mechanical Engineering, Aerospace Engineering, or a related field3 to 6 years of industry experience in mechanical design, ideally including high-altitude, pneumatic/fluidic, or release/deployment mechanismsProficiency in SolidWorks or OnShape, with a portfolio of designs taken from concept through to hardwareHands-on prototyping and testing experienceWorking knowledge of FEA, GD&T, tolerance analysis, and DFMAbility to work in austere field conditions and support changing operational schedulesU.S. citizenship with the ability to obtain and maintain a security clearanceDesirable: experience in aerospace, defense, or other high-reliability industriesDesirable: exposure to embedded systems or sensor integration, and familiarity with relevant military standardsDesirable: startup or small-company experience