Mechanical Design and Manufacturing Engineer

Key Responsibilities

• Lead the design and development of complex mechanical components and assemblies for elastomer and phenolic composite systems.
• Collaborate with cross-functional teams to define and implement scalable, high-quality manufacturing and assembly processes.
• Create and maintain process control documentation to ensure compliance, consistency, and production efficiency.
• Collaborate with Manufacturing and Quality teams to identify, capture, and implement opportunities for process improvement on existing production lines.
• Conduct trade studies and define requirements to optimize designs for radar absorption, thermal control, vibration damping, and mechanical performance.
• Perform structural analysis using hand calculations and FEA on composite structures and precision-engineered components.
• Prototype and test advanced materials (e.g., carbon fiber, silicones, urethanes), iterating based on performance data.
• Investigate material and hardware failures, lead root cause analyses, and implement corrective actions in both development and production phases.

Required Qualifications

• 3+ years of mechanical design experience, with emphasis on composites, thermal control, and vibration damping materials.
• Proven leadership in engineering projects involving design, prototyping, and manufacturing of mechanical, phenolic, and polymer-based systems.
• Hands-on experience with technical projects, including collegiate or professional work focused on advanced materials and mechanical components.
• Strong understanding of elastomer and phenolic manufacturing processes, material properties, and relevant testing standards.
• Proficient in CAD software with the ability to produce high-quality, industry-compliant engineering drawings.
• Solid grasp of engineering fundamentals including structures, materials science, thermal management, and mechanical systems.
• Skilled in prototyping and fabrication techniques such as composite compression curing, composite layups, and mechanical assembly.
• Bachelor’s degree in Mechanical Engineering or a related field, or equivalent industry experience in advanced material applications.
• Ability to communicate effectively in verbal and written English

Preferred Qualifications

• Proficient in SolidWorks or similar CAD/CAM tools, with experience using PLM systems.
• Strong knowledge of GD&T per ASME Y14.5 and its application in engineering drawings.
• Advanced design experience across CNC machining, composites, ceramics, sheet metal, and compression molding, including tooling and mold design.
• Demonstrated leadership and excellent interpersonal skills in cross-functional engineering environments.
• Familiarity with qualification campaigns for aerospace and defense hardware, including ruggedized system design.
• Experience designing for harsh environments, ensuring durability and performance under extreme conditions.
• Active U.S. Security Clearance (Secret or higher), or the ability to obtain one based on eligibility. This includes meeting background check and other requirements, as required for access to controlled defense-related information and facilities.
• Master’s degree in Mechanical Engineering or a related field, or equivalent industry experience in advanced material applications.
• Experience in an ISO 9001 or other quality-driven manufacturing environment.

Additional Requirements

Ability to communicate effectively in verbal and written English.

Ability to work in office, lab, and manufacturing environments with occasional exposure to noise, chemicals, dust, industrial equipment, and temperature variations

Must be able to lift and carry up to 35 lbs. and perform tasks involving standing, walking, bending, and manual assembly.

Visual acuity required for reading technical drawings, inspecting components, and operating precision instruments.

Occasional travel to supplier or test sites, including outdoor or industrial settings, with adherence to company and OSHA safety protocols.

Ability to safely wear required personal protective equipment (PPE), including respirators, gloves, eye protection, and protective clothing.

Ability to follow all company safety policies, OSHA requirements, and manufacturing procedures.

The above statements are intended to describe the general nature and level of work performed. They are not intended to be an exhaustive list of all responsibilities, duties, or skills required. Management may modify or assign additional duties as needed.

Job Details

FLSA Classifications: Salary (Exempt)
Type: Full Time
Salary Range: $80,000 to $140,000
Business Hours: Core Business hours (flexibility to support project needs beyond standard times)
Reports to: Head of Engineering
Base Location: Irvine, CA
Travel:  Up to 10