Bachelor's degree in Mechanical Engineering or related field
8+ years of experience in mechanical design and system integration for aerospace and defense
Proven track record in integrating mechanical subsystems into vehicles or platforms
Strong proficiency in CAD tools like SolidWorks for large assemblies
Solid understanding of mechanical interfaces and tolerancing
Familiarity with structural analysis methods and military standards
Ability to obtain and maintain a U.S. security clearance
Responsibilities
Lead mechanical integration of electronics and systems into mobile platforms
Design mechanical structures and enclosures under environmental constraints
Develop and maintain 3D CAD models and interface control documentation
Conduct structural and thermal analyses to meet military standards
Oversee system-level integration and qualification activities
Act as primary technical interface with customers and suppliers
Support production transition and resolve integration issues
Benefits
100% company-paid medical, dental, and vision benefits
401k with 50% company match up to 6%
Flexible spending accounts (FSA) and health savings accounts (HSA)
Life insurance and additional benefits
Free daily lunch and 'No meeting Fridays'
Unlimited PTO and casual dress code
Opportunities for pre-IPO stock options and relocation assistance
Full Job Description
Role Overview:
CHAOS is seeking a Principal Mechanical Engineer to provide high-value, hands-on mechanical expertise for the integration of ruggedized electronics, effectors, and mission-critical hardware into ground- and sea-mobile platforms for aerospace and defense applications. In this role, you will own and lead the design for mechanical integration of military electronics and effector systems with critical platform structures and mechanisms. Design challenges may range from compact electronics enclosures to larger structural or mechanism assemblies, depending on platform and mission requirements.
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.
The ideal candidate has strong hands-on mechanical CAD and system integration experience, demonstrated prototyping skills, a deep understanding of ruggedized hardware design, and a proven ability to work independently and guide cross-disciplinary engineering efforts.
This is a full-time, on-site position in El Segundo, CA.
Responsibilities:
Provide technical leadership and hands-on prototyping and mechanical integration of mission systems: electronics, enclosures, effectors, launchers, mechanisms, and support equipment into ground- and sea-mobile platforms
Architect and design mechanical structures, frames, mounts, enclosures, and mechanisms subject to shock, vibration, thermal, and environmental constraints
Develop and maintain 3D CAD models, assemblies, and interface control documentation (ICDs) to support multi-disciplinary system integration
Perform first-order structural and thermal analyses and requirements allocations to ensure compliance with customer requirements and applicable military standards
Lead system-level integration, qualification, and acceptance activities, including oversight of installation, alignment, and fit-check efforts
Serve as a primary technical hardware interface with customers, platform providers, suppliers, and manufacturing partners. Perform make/buy assessments
Support production transition, configuration control, and fielded system sustainment, including investigation and resolution of integration issues
Minimum Requirements:
Bachelor's degree in Mechanical Engineering or a related discipline
8+ years of progressively responsible experience in platform-level mechanical design and system integration for aerospace and defense applications
Proven experience integrating mechanical subsystems and mission systems into vehicles, mobile platforms, or fixed installations
Strong proficiency with CAD tools (e.g., SolidWorks or equivalent) for large assemblies and top-down design
Solid understanding of mechanical interfaces, tolerancing, alignment, installation practices, and interface control documents (ICDs)
Familiarity with structural analysis methods (hand calculations, FEA)
Familiarity with ruggedized military hardware and environmental qualification considerations
Experience interpreting and applying military standards, such as MIL-STD-810 and related platform qualification requirements
Demonstrated ability to lead technical decisions and resolve complex, cross-disciplinary integration challenges
Strong communication skills and ability to operate effectively in multi-project development environments
Ability to obtain and maintain a U.S. security clearance
Preferred Requirements:
Master's degree in Mechanical Engineering or a related field
Prior experience serving as a mechanical technical authority on a program
Experience with mechanisms and actuation systems, including linkages, bearings, motors, hydraulics, and pneumatics, gimbals, or rotary joints
Experience with system-level requirements allocation
Familiarity with vehicle integration constraints, including shock, vibration, transport, and operational loads
Experience with at least one commercial FEA or multiphysics simulation package (NASTRAN, ABAQUS, ANSYS, CFD codes, COMSOL, etc.)
Knowledge of manufacturing and assembly processes for mobile or deployable mechanical structures and mechanisms
Experience with prototyping, additive manufacturing, CNC machining, and other fabrication techniques
Familiarity with military-style connectors (e.g., mil-circular 38999, ARINC, micro-D)
Why CHAOS?
Health Benefits: Medical, dental, and vision benefits 100% paid for by the company
Additional benefits: 401k (+ 50% company match up to 6% of pay), FSA, HSA, life insurance, and more
Compensation Components: Competitive base salaries, generous pre-IPO stock option grants, relocation assistance, and (coming soon!) annual bonuses
Team Growth: 200 employees and counting across 5 global offices
$175k-215k
The stated compensation range reflects only the targeted base compensation range and excludes additional earnings such as bonus, equity, and benefits. If your compensation requirements fall outside of the range, we still encourage you to apply. The salary range for this role is an estimate based on a range of compensation factors, inclusive of base salary only. Actual salary offer may vary based on (but not limited to) work experience, education and/or training, critical skills, and/or business considerations.
