Responsibilities

CHAOS is seeking a Senior Mechanical Engineer to own the mechanical design and productization of the passive RF geolocation sensors in our electromagnetic warfare product line. Our Spectrum Sensing Team has developed and fielded a working prototype of a distributed TDOA geolocation sensor. Now we need an engineer who can turn it into a rugged, repeatable product that can be manufactured and deployed in fixed-site, mast-mounted, and ground-vehicle configurations.
The ideal candidate has taken ruggedized electronics hardware from prototype through qualification and into production, is fluent in DFM/DFA, and enjoys being hands-on in a small, fast-moving, cross-disciplinary team.
This is a full-time, on-site position in Washington, D.C.
As the mechanical lead for the Spectrum Sensing Team's productization effort, the Senior Mechanical Engineer will:
Own the mechanical architecture and detailed design of the sensor node, including enclosures, chassis, internal structures, brackets, cable management, and external interfaces
Design fixed-site (mast, tower, and rooftop) and ground-vehicle mounting solutions, including quick-deploy, leveling, and alignment features as needed
Lead thermal design and analysis for sealed outdoor electronics, including heat sinking, thermal interface materials, solar loading, and passive and active cooling tradeoffs
Design for environmental robustness, including ingress protection (IP67 or equivalent), sealing, corrosion resistance, shock, vibration, humidity, and temperature extremes, in line with MIL-STD-810 and customer requirements
Partner with RF and electrical engineers on antenna and RF integration, GPS/GNSS and timing-reference mounting, EMI/EMC shielding and grounding, and connector selection to support MIL-STD-461 and system performance
Perform first-order structural, thermal, and tolerance analyses (hand calculations and FEA) to drive design decisions and requirements allocation
Apply DFM/DFA principles and work with Manufacturing Engineering and suppliers to drive down cost, part count, and assembly time
Create and release production-quality CAD models, drawings with GD&T, mechanical BOMs, and interface control documents (ICDs)

Senior Mechanical Engineer, RF Sensor Productization at Chaos Industries · LumiJobs

Senior Mechanical Engineer, RF Sensor Productization

Responsibilities

Qualification

Preferred

Benefits

Company

Chaos Industries

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