{"id":3484957,"url":"https://alion.io/job/maxtena-senior-mechanical-engineer","title":"Senior Mechanical Engineer","company":{"id":678578,"name":"Maxtena","domain":"maxtena.com","url":"https://alion.io/company/maxtena","size_band":"51-200","is_staffing_agency":false,"employer_type":"direct","is_intermediary":false,"listed_via":null,"ats_vendor":"BambooHR","truth_index":null},"role":"Industrial Engineering","role_family":"Industrial Engineering","seniority":"senior","employment_type":"full_time","work_mode":"on_site","remote_scope":null,"remote_scope_basis":null,"remote_working_hours":null,"hiring_geo_confidence":"explicit","locations":["Germantown, United States"],"countries":["US"],"hiring_countries":[],"hiring_countries_total":0,"salary":null,"salary_estimate":{"min_usd":83000,"max_usd":156000,"period":"year","method":"role_seniority_country_remote_cell","sample_n":6333},"experience_years_min":8,"visa_sponsorship":false,"relocation_package":false,"has_equity":false,"technologies":[{"name":"ANSYS","optional":true},{"name":"GD&T","optional":true},{"name":"SolidWorks","optional":true}],"status":"live","first_seen_at":"2026-10-29T21:28:17Z","employer_posted_date":"2026-10-29","last_verified_at":"2026-11-04T14:43:59Z","board_verified":true,"closed_at":null,"days_open":5,"trust":{"level":"ok","repost_count":null,"flags":[],"days_open":5},"description":"The Senior Mechanical Engineer is responsible for leading the design, development, analysis, and testing of mechanical systems and components. This is a hands on role, that is essential in leading full product lifecycle from concept through production and ensures designs meet technical, quality, and regulatory requirements. The Senior Mechanical Engineer collaborates cross-functionally, mentors junior engineers, and contributes to continuous improvement and innovation initiatives.\nEssential Duties and Responsibilities:\nLead the mechanical design of small, complex electronics enclosures from concept through production.\nDesign and optimize EMI/RF shielding, including enclosure architecture, seams, joints, gaskets, interfaces, and grounding strategies.\nDevelop RF-transparent radome and RF window designs, balancing electromagnetic performance with mechanical strength, environmental durability, manufacturability, and appearance.\nDevelop mechanical and thermal solutions for high-density electronics, including conduction cooling, heat spreading, heat sinks, thermal interfaces, and passive cooling strategies.\nDesign for demanding environmental conditions, including water ingress, dust, vibration, shock, temperature extremes, corrosion, and outdoor exposure.\nSelect appropriate materials, coatings, finishes, seals, gaskets, adhesives, and joining methods for demanding applications.\nPerform mechanical analysis and engineering calculations, including thermal, structural, tolerance, and vibration analysis as appropriate.\nCreate detailed 3D CAD models, drawings, assemblies, and engineering documentation.\nWork directly with prototype shops, suppliers, and manufacturing partners to develop and refine designs.\nBuild and test prototypes, investigate failures, and drive design improvements.\nParticipate in environmental, EMI/EMC, RF, thermal, and mechanical qualification testing.\nMentor junior mechanical engineers and provide technical leadership on complex design problems.\nContribute to engineering standards, design methodologies, and product development processes.\nPreferred Qualifications:\nMust be a U.S. Citizen with the ability to obtain Secret Clearance.\nBachelor’s degree in Mechanical Engineering or related field, Master’s degree preferred.\n8+ years of mechanical design and engineering experience, developing & designing electromechanics experience preferred.\nProficiency in CAD software (SolidWorks) FEA and thermal analysis tools.\nDemonstrated understanding of GD&T, tolerance analysis, mechanical drawings, and configuration-controlled engineering.\nExperience with structural and/or thermal analysis tools, such as Solidworks Simulation or ANSYS.\nStrong understanding of materials, manufacturing processes, and mechanical systems.\nExcellent problem-solving, communication, and documentation skills.\nExperience in aerospace, defense, RF systems, or high-precision manufacturing.\nDemonstrated hands on experience with die casting, CNC machining, sheet metal, composite molding and additive manufacturing.\nAdvanced proficiency with full cycle 3D printer protype builds.\nDemonstrated ability working in cross-functional development teams\nMaxtena is an Equal Opportunity Employer. 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