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Salary: USD 140,000 - 180,000 / annual
Mach Industries, a rapidly growing defense technology company founded in 2023 with ~350 employees, is seeking a Senior Mechanical Design Engineer with avionics integration expertise to join their Huntington Beach team. You will design, integrate, and test electro-mechanical systems for next-generation autonomous defense platforms.
In this hands-on role, you will develop avionics mounting architectures, electronics enclosures, PCBA mounting solutions, wire harness accommodation, connector interfaces, EMI/EMC mitigation, and thermal management solutions for flight-ready hardware. You'll take avionics systems from concept through hardware bring-up, environmental testing, and flight qualification, collaborating closely with electrical, firmware, systems, manufacturing, and test teams to create rugged, serviceable, and manufacturable hardware built for demanding aerospace environments.
Key Responsibilities:
- Design and develop avionics or PCBA mounting architectures and enclosures via CAD design and engineering release, including GD&T per ASME Y14.5
- Work cross-functionally with electrical engineering teams to develop and verify overall architecture, schematics, and layout via ECAD/MCAD data exchange and ICD documentation
- Design avionic accommodation including shock and vibration isolation, serviceability, connector access, EMI/EMC mitigation, grounding, shielding, thermal management, and reliability
- Develop and execute environmental qualification testing for integrated avionics assemblies, including vibration, shock, thermal cycling, ingress protection, and EMI/EMC
- Design fixtures and tooling to manufacture, inspect, qualify, and test avionics hardware
- Author test plans, technical documentation, and engineering milestones for cross-team and leadership review
- Support critical development and test milestones, including occasional extended hours and weekends as needed
Required Qualifications:
- 6+ years of experience in mechanical engineering with a focus on avionics integration, electronics packaging, or wire harness design
- Strong experience with 3D CAD tools (NX, SolidWorks, or equivalent) for mechanical design and detailed drawings, including expertise in GD&T per ASME Y14.5
- Practical experience with enclosure design, wire harness routing/integration, and EMI/EMC mitigation techniques
- Bachelor's degree in Mechanical Engineering, Aerospace Engineering, Electrical Engineering, or a related field
- Demonstrated hands-on experience owning end-to-end hardware development and integration efforts (e.g., student aerospace/rocketry teams, UAV projects, automotive electronics integration, or similar)
Preferred Qualifications:
- Advanced degree (Masters or PhD) in Mechanical Engineering, Aerospace Engineering, Electrical Engineering, or a related field
- Experience with environmental acceptance/qualification testing of avionics (vibration, shock, thermal, IP testing)
- Working knowledge of thermal management and layout best practices for electronics
- Experience evaluating PCBA structural response, including first-order analytical methods, FEA, vibration response, and Steinberg-type fatigue assessment
- Experience with design and release of wire harnesses, including routing, connector selection, strain relief, bend-radius compliance, abrasion protection, shielding termination, grounding schemes, and maintainability
- Experience collaborating closely with electrical engineering teams on layout, connector selection, grounding, and shielding
- Knowledge of aerospace or defense standards and requirements for avionics integration
Note: ITAR compliance required. Applicant must be a U.S. citizen, national, lawful permanent resident, Refugee, or Asylee, or be eligible to obtain required authorizations from the U.S. Department of State.
