Senior Mechanical Engineer

CHAOS Industries is redefining modern defense with a multi-product portfolio that gives the ultimate advantage—domain dominance. The company’s products are powered by Coherent Distributed Networks (CDN™), empowering warfighters, commercial air operators, and border protection teams to act faster, adapt rapidly, and stay ahead of evolving threats.

Role Overview

CHAOS is seeking a Senior Principal Mechanical Design Engineer to serve as the technical authority for the design, integration, and qualification of electronic hardware and enclosures for aerospace and defense applications. This role is responsible for setting mechanical direction across programs, solving complex design challenges, and ensuring technical excellence from concept through qualification, production, and sustainment.

The ideal candidate brings deep hands-on mechanical design expertise, strong CAD and packaging experience, and a proven ability to independently lead cross-disciplinary technical efforts spanning mechanical, electrical, RF, power, and systems engineering.

This is a full-time, on-site position in Hawthorne, CA.

Responsibilities

• Architect and design ruggedized electronic hardware and enclosures, including chassis, card-level packaging, mounting features, and thermal solutions, in accordance with program requirements and applicable standards
• Define and maintain mechanical architectures, interfaces, and design approaches to support multi-disciplinary system integration.
• Develop and oversee 3D CAD models, assemblies, drawings, and interface control documentation (ICDs), ensuring production-ready quality and configuration control.
• Perform first-order structural and thermal analyses to support design decisions and verify compliance with environmental and performance requirements
• Perform and/or review first-order structural and thermal analyses to support design decisions and verify compliance with environmental and performance requirements
• Lead cross-disciplinary technical resolution involving mechanical, electrical, RF, power, and systems engineering teams
• Serve as a primary technical hardware interface with customers, platform providers, suppliers, and manufacturing partners.
• Perform make/buy assessments with manufacturing partners as required
• 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
• 4+ years Relevant experience in mechanical design and integration of electronic hardware for aerospace, defense, or similar applications
• Strong proficiency with mechanical CAD tools (e.g., SolidWorks or equivalent) and experience producing production-ready drawings
• Experience designing mechanical hardware for RF, avionics, power electronics, and/or embedded computing products
• Solid understanding of mechanical drafting standards, GD&T, tolerance analysis, and configuration-controlled documentation
• Experience supporting prototype builds, integration, and qualification testing
• Strong problem-solving skills, attention to detail, and ability to work effectively in fast-paced development programs
• Ability to obtain and maintain a U.S. security clearance
  

Preferred Requirements

• Master’s degree in Mechanical Engineering or a related field
• Advanced experience with SolidWorks for complex parts and assemblies
• Experience with commercial FEA or multiphysics simulation tools (e.g., NASTRAN, ABAQUS, ANSYS, COMSOL, CFD tools)
• Familiarity with military specifications and standards (e.g., MIL-STD-810)
• Familiarity with military and aerospace connectors (e.g., MIL-DTL-38999, ARINC, Micro-D)
• Experience supporting environmental qualification testing and analysis (e.g., thermal cycling, vibration, shock)
• Experience supporting cable harness routing, connector layouts, and electromechanical integration
• Experience with additive manufacturing, CNC machining, and prototype fabrication techniques
• Hands-on experience working with machine shop and prototype lab equipment
  

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
• Our Perks: Free daily lunch, ‘No meeting Fridays’, unlimited PTO, casual dress code
• 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
  

Salary Range: $150,000 – $190,000

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.

Recruiting Agencies: CHAOS Industries does not accept unsolicited resumes or outreach. Unsolicited submissions will not be reviewed or compensated.