Principal Mechanical Engineer – Phased Array Radar Systems

Overview

Hybrid
Depends on Experience
Full Time

Skills

Mechanical

Job Details

Principal Mechanical Engineer – Phased Array Radar Systems


Location: Onsite / Hybrid – Richardson TX (DFW area)
Employment Type: Full-Time
Clearance: .  Ability to obtain to Secret clearance

Position Overview
We are seeking a Principal Mechanical Engineer to lead the mechanical design, system integration, and production manufacturing of phased-array radar systems used in advanced defense and aerospace applications. This role owns the physical architecture of the radar subsystems and array, working closely with RF, electrical, thermal, manufacturing, and systems engineering teams to deliver ruggedized, high-performance hardware from concept through deployment.

Key Responsibilities
Technical Leadership & System Design
  • Serve as Chief Engineer for all mechanical aspects of the radar and contribute as the technical authority for system integration requirements
    • Responsible for design release and sign-off to production
    • Lead architecture discussions and decision between teams
    • Document trade studies and analyses of cost/performance details

    Mechanical Design & Analysis
    • Structural design and analysis of integrated electromechanical system components at both prototype and mass manufacture scales
      • Integrated FEA analysis of components to meet thermal and mechanical requirements for both commercial and military specifications
      • Adaptation of RF and EE design requirements into CAD designs
      • Specification of cable assemblies, terminations, and compact routing
      • Design & Detail of complex machine assembly methods
      • Management of varied manufacturing methods, including Sheet Metal, CNC, Extrusion, Brazing, Welding, PCBA, Glue-Up, Assembly Jigs, and Test Stands
    • System design across thermal, power, and mechanics to meet diverse engineering and business requirements.
      • Manage vendor relations on sourced components and serve as technical authority on component specifications
      • Perform multi-domain design studies across varied system configurations
      • Interface with manufacturing and assembly teams to coordinate responsibilities and handoffs
      • Design & Test of high load thermal management and cooling systems
      • Integration of high voltage field power generators with human operators
      • Lifecycle design including operational and service aspects of the radar assembly, system components, and deployment equipment in varied environments
      • Maintenance of professional standards across teams and functions
        • Design Release cycles, drawing packets, GD&T, DFM, ISO 9001, ISO-MIL, AS9100, sourcing, manufacturing standards, etc.
        • Perform Design Reviews and revision control
        • Support manufacturing across the company, providing DFM for prototyping, pilot, and production runs, both in-house and with CM’s, serving engineering and business
          • Design for manufacturability and high-reliability production
          • Support prototype builds and production scaling
          • Participate in failure analysis and corrective actions
            Required Qualifications
            • Bachelor’s degree in Mechanical Engineering (Master’s preferred)
            • 10+ years of experience in defense, aerospace, radar, or similar systems
            • Experience with phased-array radar or related RF electromechanical hardware
            • Proficiency with CAD tools (SolidWorks preferred), FEA Simulation, and thermal models
            • Strong background in structural, thermal, and vibration analysis
            • Ability to obtain and maintain a U.S. security clearance

            Preferred Qualifications
            • Experience with AESA radar systems and high-power RF electronics
            • Experience with complex machine design and production lifecycles
            • -Rapid R&D prototyping methods and translation to scaled production processes in aerospace materials and tooling
            • Familiarity with RF materials and design rules for radomes, enclosures, and antennas

             

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            About Catapult Solutions Group