BAE Systems is seeking a skilled and motivated Sr Mechanical Engineer to join our team and contribute to the design and development of innovative mechanical solutions for electronic test assemblies and systems. This role requires a background in mechanical engineering, expertise in design and analysis, with an understanding of test hardware designs.
The ideal candidate will demonstrate excellent leadership and communication skills, strong problem-solving abilities, and the capacity to work effectively both independently and within a team environment.
Key Responsibilities:
- Develop robust hardware solutions to meet demanding customer requirements, including test hardware.
- Perform / assess detailed design and analyses, including thermal and structural analyses as needed
- Generate / assess 3D solid models, utilize GD&T principles, and perform tolerance analyses to ensure fit and function
- Generate/ assess designs against environmental requirements and generate prototypes for test and verification efforts
- Strong background in mechanical engineering with expertise in design and analysis
- Excellent leadership and communication skills
- Experience in the design, development, and testing of mechanical test hardware.
- Experience working with integrated military electronic hardware and related test equipment
- Ability to work individually and in small team environments
- Strong problem-solving skills and ability to execute complex projects
- Knowledge of test engineering principles and practices.
Because of the need for consistent, in-person collaboration and/or the requirement to perform all work onsite due to the nature of this particular role, it will be performed full-time on site.
Required Education, Experience, & Skills
Education and Experience
- Bachelor's degree in Mechanical Engineering
- 6+ years' experience in mechanical engineering
Technical Skills
- Solid fundamentals of mechanical design, analysis and documentation principles
- Solid fundamentals of mechanical design, analysis, and documentation principles
- Experience with state-of-the-art mechanical engineering development software tools (ANSYS Workbench/Mechanical, PTC Creo, MATLAB, etc)
Security Clearance
- Must be able to obtain a Secret Clearance
Preferred Education, Experience, & Skills
- Knowledge/experience with manufacturing, production, and sustainment of mechanical systems and hardware
- Knowledge of design for manufacturing (DFM) principles
Soft Skills
- Excellent leadership and communication skills
- Strong written and verbal communication skills
- Ability to work individually and in team environments
- Strong problem-solving skills and ability to execute complex projects
- Motivated self-starter and problem solver with proven experience executing in multi-disciplinary teams
Pay Information
Full-Time Salary Range: $88189 - $149922
Please note: This range is based on our market pay structures. However, individual salaries are determined by a variety of factors including, but not limited to: business considerations, local market conditions, and internal equity, as well as candidate qualifications, such as skills, education, and experience.
Employee Benefits: At BAE Systems, we support our employees in all aspects of their life, including their health and financial well-being. Regular employees scheduled to work 20+ hours per week are offered: health, dental, and vision insurance; health savings accounts; a 401(k) savings plan; disability coverage; and life and accident insurance. We also have an employee assistance program, a legal plan, and other perks including discounts on things like home, auto, and pet insurance. Our leave programs include paid time off, paid holidays, as well as other types of leave, including paid parental, military, bereavement, and any applicable federal and state sick leave. Employees may participate in the company recognition program to receive monetary or non-monetary recognition awards. Other incentives may be available based on position level and/or job specifics.
About BAE Systems, Inc.
BAE Systems, Inc. is a defense, aerospace, and security company headquartered in Falls Church, Virginia, with more than 40,000 employees worldwide. We serve, supply, and protect those who protect us. As one of the most geographically diverse international defense companies, we deliver a full range of products and services spanning air, land, maritime, space, and cyber, including advanced electronics, intelligence solutions, and dedicated customer support.
Our culture is performance-driven and values-led, built on curiosity, creativity, and collaboration. Purpose isn't a tagline here. It's what drives us. We're developing breakthrough technologies that defend national security and make a lasting impact on our communities and our planet. When you join BAE Systems, you're not just building a career. You're contributing to a mission that truly matters.
This position will be posted for at least 5 calendar days. The posting will remain active until the position is filled, or a qualified pool of candidates is identified.
Skills Required
- Bachelor's degree in Mechanical Engineering
- 6+ years of experience in mechanical engineering
- Strong mechanical engineering design, analysis, and documentation skills
- Experience designing, developing, and testing mechanical test hardware
- Experience with integrated military electronic hardware and related test equipment
- Knowledge of test engineering principles and practices
- Experience with mechanical engineering development software such as ANSYS Workbench/Mechanical, PTC Creo, or MATLAB
- Ability to obtain a Secret clearance
- Knowledge or experience with manufacturing, production, and sustainment of mechanical systems and hardware
- Knowledge of design for manufacturing principles
BAE Systems, Inc. Compensation & Benefits Highlights
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Retirement Support — Retirement benefits stand out with a 401(k) savings plan and company matching, emphasizing long-term financial security. This area is consistently positioned as one of the stronger components of the package.
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Parental & Family Support — Family programs are notably broad, including paid parental leave, adoption and surrogacy reimbursement, dependent‑care accounts, and child‑ and elder‑care resources. In the U.S., up to 10 subsidized days of backup care per year further support caregivers.
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Healthcare Strength — Health coverage spans medical, dental, and vision options alongside HSAs/FSAs, mental‑health support, and an Employee Assistance Program. The breadth of offerings provides solid baseline protection across common healthcare needs.
BAE Systems, Inc. Insights
What We Do
Improving the future and protecting lives is an ambitious mission, but it’s what we do. As a leading aerospace, defense, and security company, we work together to deliver a full range of products and services for air, land, space, and naval forces, as well as advanced electronics, security, information technology solutions and customer support services. How we work is rooted in purpose – a purpose to protect those who protect us, to unite our community of colleagues and customers, and to drive forward the growth and development of our exceptional team members. It's where purpose connects.
Why Work With Us
We believe your career should be filled with innovation and discovery. And that's exactly what you'll find at BAE Systems. As you work to develop the latest technology and defend national security, you will continually hone your skills and expand knowledge. On a sharp and collaborative team, you will be challenged – and supported – at every turn.
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Hybrid Workspace
Employees engage in a combination of remote and on-site work.
As the work place continues to evolve, so do we. Remote and hybrid opportunities are available at BAE Systems depending on the nature of the role. Check your job requisition to learn more.








