Sr. Principal Mechanical Engineer (Structural Analysis SME)

Job Description
BAE Systems is seeking a Principal Mechanical Engineer to serve as a Subject Matter Expert (SME) in structural analysis. This role is critical in ensuring the structural integrity, durability, and survivability of innovative mechanical solutions for dynamic electronic military systems.
The ideal candidate will possess a deep background in structural mechanics and finite element analysis (FEA), excellent leadership skills, and a proven track record of driving structural validation from the IRAD/Proposal phase through to the Qualification phase.
Key Responsibilities
Technical Leadership & Structural Oversight: Provide lead structural oversight for entire projects, complex modules, or high-stress LRUs/boxes, operating with high autonomy to ensure all hardware meets rigorous structural requirements.
Analysis Authority: Hold primary responsibility and authority for structural analysis. Utilize advanced simulation techniques to predict failure modes, optimize weight, and ensure structural margins are maintained.
Business Pursuit & Customer Engagement: Support key business pursuits by defining structural requirements and environmental constraints that meet customer needs; serve as the primary technical point of contact for structural integrity during customer interfaces.
Structural Validation & Development: Develop and validate robust structural solutions to meet demanding customer requirements and military environmental specifications (e.g., MIL-STD-810).
SME Analysis & Review: Act as the Structural Engineering Subject Matter Expert (SME) and reviewer; perform high-level complex stress, modal, and shock analyses and present results effectively to program leadership and customers.
Project Integration: Collaborate across disciplines to ensure that structural constraints are balanced with thermal and electrical requirements, and that technical risks are fully understood and mitigated.
Business Initiative Driver: Promote and implement strategic initiatives, including advanced simulation workflows, standardized structural reporting, and rigorous peer review processes for analysis reports.
Team Mentorship: Lead and mentor a team of engineers, guiding them in the application of structural analysis best practices and developing their skills to advance into future technical leadership roles.
Detailed Execution: Generate and assess complex FEA models, perform hand calculations for verification, conduct tolerance stack-up analyses, and define test parameters for structural verification efforts.
Required Education, Experience, & Skills
Education and Experience

• Bachelor's degree in Mechanical Engineering.
• 6+ years' experience in mechanical/structural engineering.

Technical Skills

• Expert fundamentals of structural analysis, stress/strain, and fatigue documentation principles.
• Mastery of state-of-the-art structural analysis software tools (e.g., ANSYS Mechanical, Nastran/Patran, Abaqus, MATLAB, etc.).
• Knowledge of material properties for aerospace/defense applications and experience with the production and sustainment of structural mechanical systems.

Security Clearance

• Must be able to obtain a Secret Clearance.

Preferred Education, Experience, & Skills
Soft Skills

• Motivated self-starter and problem solver with proven experience executing in multi-disciplinary teams.
• Strong written and verbal communication skills.
• Ability to maintain a high-level strategic view of structural integrity while managing detailed simulation execution

Pay Information
Full-Time Salary Range: $132962 - $226035
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 Electronic Systems
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.