We are seeking a skilled Mechanical Engineer to design and develop sheet metal enclosures and packaging solutions for PCB assemblies and power supplies used in military and aerospace applications. This role requires expertise in precision sheet metal design, thermal management, and ruggedized packaging that meets stringent military specifications and aerospace standards.
Key Responsibilities
Design and develop sheet metal enclosures, chassis, and packaging solutions for PCB assemblies and power supply units intended for military and aerospace applications. Create detailed 3D CAD models and 2D manufacturing drawings using industry-standard software, ensuring designs are optimized for sheet metal fabrication processes including forming, bending, stamping, and welding. Perform thermal analysis and design appropriate cooling solutions such as heat sinks, ventilation patterns, and thermal interfaces to ensure components operate within specified temperature ranges in harsh environments.
Ensure all designs comply with relevant military standards (MIL-STD-810, MIL-STD-461, MIL-DTL-901) and aerospace specifications, including shock, vibration, EMI/EMC shielding, and environmental sealing requirements. Collaborate closely with electrical engineers to understand PCB layouts, component placement, connector requirements, and electrical grounding needs. Select appropriate materials and finishes that meet corrosion resistance, weight limitations, and durability requirements for the intended operating environment.
Develop prototypes and coordinate with manufacturing teams and external vendors to ensure designs are manufacturable, cost-effective, and meet quality standards. Conduct design verification testing including shock, vibration, thermal cycling, and environmental testing. Support qualification and certification processes required for military and aerospace applications. Participate in design reviews, failure analysis, and continuous improvement initiatives.
Required Qualifications
Bachelor's degree in Mechanical Engineering or related field with 3-5 years of experience in sheet metal design for electronics packaging. Proficiency in 3D CAD software (SolidWorks, CREO, or similar) with strong understanding of sheet metal design principles and manufacturing processes. Knowledge of military specifications (MIL-STD) and aerospace standards applicable to mechanical design and electronics packaging. Experience with thermal analysis tools and understanding of heat transfer principles in electronic systems.
Strong understanding of materials selection, particularly aluminum alloys, stainless steel, and specialty coatings for harsh environments. Familiarity with EMI/RFI shielding techniques and grounding requirements. Ability to read and interpret electrical schematics and PCB layouts. Experience with GD&T and creating detailed manufacturing drawings.
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