Sr. Mechanical Engineer
Confirmed on the employer's own hiring board on Nov 15, 2026. First seen by Alion on Sep 25, 2026.
About Roguebeam
Roguebeam is a startup developing advanced phased array systems for communications and radar applications. We design and manufacture complete systems in-house-RF, antenna, PCB, ASIC/digital, DSP, and mechanical-giving our engineers end-to-end ownership of the technology and a direct line of sight from design to deployed system. We're early, we're growing fast, and the people who join us now will shape both the technology and the company.
The Role
We're looking for a Senior Mechanical Engineer to own the mechanical design of our radar sensor nodes end-to-end-the array panels, enclosures and thermal systems that let a phased array survive and perform outdoors at a low cost. You'll drive designs from concept through qualification and production, working directly with our RF, antenna, and electronics teams. As an early mechanical hire, you'll have an outsized impact on how our radar systems are architected, built, and scaled.
What You'll Do
Own the mechanical design of radar sensor nodes from concept through production, including array panel structure, enclosure and mounting.
Thermal management: conduction paths from beamformer ICs and power electronics through the array panel to ambient, including heat spreaders, heat sinks, solar loading, and thermal test correlation.
Array panel structure: flatness and stiffness of large multilayer RF PCBs, tolerance stack-ups, RF shielding and cavity isolation, EMI gasketing, and connector/interconnect mechanics.
Environmental ruggedization: IP67 sealing, shock and vibration, temperature cycling, humidity, salt fog, and UV exposure for systems deployed outdoors year-round.
Design for manufacturing: low-cost, volume-ready designs using die casting, sheet metal, injection molding, and CNC; complete drawing packages with GD&T.
Lead thermal and structural analysis: define test plans, and correlate models with measured data.
Plan and execute environmental qualification testing.
Assembly/testing process: define/design tooling and fixtures required to assemble and test products at rate.
Select and manage fabrication and assembly vendors; drive cost reduction as volumes grow.
Define mechanical requirements and interfaces with RF, antenna, electronics, and systems engineers.
What You Bring
BS in Mechanical Engineering or a related field.
5-10 years of experience in mechanical design of electronics hardware, including at least one product taken through to production.
Demonstrated ownership of thermal design for high-power-density electronics.
Experience designing sealed, ruggedized enclosures for outdoor deployment.
Expert proficiency in 3D CAD (NX, Creo, Catia, SolidWorks, or similar)
Expert proficiency in GD&T (ASME Y14.5).
Strong skills in thermal and structural FEA (e.g., NASTRAN, Ansys, FloTHERM, Icepak, Thermal Desktop).
Direct experience with fabrication vendors and design for manufacturing at volume.
Hands-on lab skills for prototyping and test.
Nice to Have
MS in Mechanical Engineering.
Mechanical design experience with phased arrays, antennas, or radar systems.
Environmental qualification experience (e.g., MIL-STD-810, MIL-STD-461, IEC 60529, SMC-S-016).
Experience designing for low-cost manufacturing (die casting, injection molding).
Startup or small-team experience.
Why Roguebeam
This is a rare ground-floor opportunity. Joining a startup at this stage means your work has a direct, visible effect on whether the company succeeds-and a corresponding upside as we grow. Because we build the entire system in-house, you'll see your mechanical designs integrated into real phased arrays and deployed in working systems, not handed off and forgotten. You'll have real ownership and a seat at the table on technical direction.
Additional Notes
This position requires access to technology and technical data subject to U.S. export control regulations (ITAR/EAR). Applicants must be U.S. persons (U.S. citizens, U.S. lawful permanent residents, or individuals granted asylum or refugee status) or otherwise eligible to access export-controlled information without a license.