Staff Mechanical Engineer
Confirmed on the employer's own hiring board on Oct 6, 2026. First seen by Alion on Sep 29, 2026. Applied Research Associates scores B on the Alion truth index.
ARA's Engineering Science Division is seeking a highly skilled and multidisciplinary mechanical engineer to join our team. The ideal candidate will be equally strong in mechanical engineering and modern C++ software development, with hands-on experience designing, prototyping, modeling, and simulating advanced robotic and mechatronic systems. This role involves building sophisticated mechanical components and integrated systems, while also developing the software that drives, simulates, and validates them. Candidates must be comfortable working across hardware and software boundaries, creating tightly coupled designs that span CAD modeling, physical prototyping, embedded programming, and high-performance real-time C++ development.
This is an on-site position located in San Antonio, TX.
U.S. citizenship is required. Candidates selected may be subject to a government security investigation and must meet eligibility requirements for access to classified information.
What you will do as a staff mechanical engineer:
- Design, implement, and optimize high-performance C++ code for embedded systems, robotics control, autonomy, and simulation infrastructure.
- Develop detailed mechanical designs, assemblies, and engineering drawings in SolidWorks, ensuring manufacturability, structural integrity, and system integration.
- Create, maintain, and optimize virtual models of robotic and mechanical systems, using simulation frameworks to validate and refine behavior, dynamics, and control algorithms prior to physical deployment.
- Build, analyze, and test mechatronic systems involving sensors, actuators, electronics, and custom mechanical components.
- Use ROS/ROS2, Docker, Linux, and other development tools to create robust software architectures for simulation, autonomy, perception, and hardware integration.
- Conduct mechanical analysis including stress analysis, tolerance stack-ups, material considerations, and dynamic modeling.
- Prototype and iterate rapidly using 3D printing, machining, and assembly of electromechanical systems.
- Analyze data from simulations and physical hardware testing to improve performance, debug complex interactions, and refine system behavior.
- Collaborate closely with mechanical, electrical, software, and systems engineering teams to deliver integrated robotic and electromechanical solutions. Produce clear, organized, and technically rigorous documentation for both mechanical and software systems.
Staff mechanical engineer requirements:
- Bachelor’s degree in Mechanical Engineering, Mechatronics, Computer Engineering, or a related field.
- 5-7 years of combined mechanical engineering and software development experience. Advanced degrees may partially substitute for experience.
- Expert-level proficiency in modern C++ (C++11/14/17 or higher) for embedded, real-time, and robotics systems.
- Extensive hands-on experience with SolidWorks for 3D modeling, 2D drawings, mechanical assemblies, and design documentation.
- Demonstrated experience with robotics, mechatronics, or electromechanical systems, including actuation, sensors, and system integration.
- Proficiency with Linux development, command-line tools, Git-based workflows, and Docker containers.
- Experience developing and using simulation environments for robotic or mechanical system modeling (e.g., Gazebo, custom physics engines).
- Strong analytical skills and the ability to diagnose system behavior across mechanical, electrical, and software components.
- Ability to prototype, test, and iterate designs quickly, both virtually and physically.
- Strong technical writing and documentation discipline.
Preferred experience:
- Experience in Unreal Engine for advanced robotic or mechanical simulation.
- Familiarity with unmanned underwater vehicles, surface vehicles, Navy systems, or other mission-critical platforms.
- Hands-on experience with robotics frameworks such as ROS2, DDS, or custom real-time messaging systems.
- Background in wearables, autonomous systems, heavy machinery, or ruggedized mechanical hardware.
- Portfolio demonstrating real-world projects combining C++ development with mechanical design, robotics, or mechatronics.
- Experience with AI/ML applied to mechanical system performance, perception, or autonomy.
About ARA:
ARA is an employee-owned international research and engineering company recognized for providing technically superior solutions to complex and challenging problems in the physical sciences. The company, founded in Albuquerque, NM, in 1979, currently employs more than 2,200 professionals and continues to grow. ARA offices throughout the United States and Canada provide a broad range of technical expertise in computer software and simulation, environmental technologies, defense technologies, systems analysis, civil technologies, and testing and measurement. The corporation also provides sophisticated technical products for robotics, environmental site characterization, and pavement analysis.
At ARA, employees are our greatest assets. The corporation realizes that employee ownership spawns greater creativity and initiative along with higher performance and customer satisfaction levels. ARA gives its employees the tools, training, and opportunities to take more active roles as owners. The culture is challenging; innovation and experimentation are the norm. Employees are eligible for contributions which not only add to the company’s success, but also their own through the Employee Stock Ownership Plan (ESOP). The motto, “Engineering and Science for Fun and Profit” sums up the ARA experience.