Principal Mechanical (Design) Engineer

Job Title: Principal Mechanical (Design) Engineer

Job Summary:

Leads the mechanical design of electro‑optical (EO) systems and opto‑mechanical assemblies from concept through production.

Designs major components or major portions of a functional system to develop or improve products and facilitate manufacturing operations.

Translates customer and market requirements into robust mechanical architectures, balancing performance, manufacturability, cost targets, and configuration control.

Utilizes CAD/PLM tools to create detailed models, drawings, and documentation; performs mechanical and thermal analyses; and works as a cross‑functional liaison to ensure seamless system integration and production readiness.

Coaches and trains junior and senior engineers, establishes reusable design patterns and playbooks, and serves as final technical approver for critical designs.

Responsibilities and Tasks:


* Own the mechanical architecture and design of electro‑optical enclosures, precision mounts, thermal frames, seals, and structural elements.

Ensure optical alignment stability, thermal management, EMI/ESD robustness, and environmental durability.


* Create 3D CAD models, detailed drawings, and engineering documentation per internal standards (Creo Parametric preferred; Windchill PLM).


* Generate system‑level mechanical layouts and thoroughly detailed component designs with minimal supervision.

Perform component‑level and assembly‑level tolerance analyses and stack‑ups to guarantee fit, function, and alignment.


* Analyze and optimize designs using structural (FEA) and thermal simulations (Ansys or Creo Simulation), material selection, finishes, and fabrication processes to meet performance and reliability goals.

Translate CTQs into tolerance budgets and verify with analytical stack‑ups and build data.


* Design for manufacturing and cost: apply DFM/DFA and Design‑to‑Unit‑Production‑Cost (DTUPC) principles.

Partner with manufacturing engineering to design or revise tooling, fixtures, and assembly methods.


* Document Critical‑to‑Quality (CTQ) characteristics for purchased parts and assemblies.

Define drawing GD&T and datum strategies; Lead tolerance analysis, approve component‑level and assembly‑level stack‑ups, select worst‑case or statistical approaches, and correlate tolerance budgets to supplier capability and inspection plans


* Own supplier technical engagement: define capability targets (Cp/Cpk) for CTQs, review first articles, and resolve process gaps; escalate and lead corrective actions.


* Prepare for and lead/contribute to design reviews (internal and external), risk assessments (DFMEA/PFMEA), and reliability planning; participate in peer reviews of complex mechanical approaches.

Present tolerance budgets, key stack‑ups, and inspection plans.


* Prototype, assemble, and debug early units; support fabrication, inspection, and iterative refinement; assist production d...