Sr Principal Opto-Mechanical Design Engineer (Aerospace & Defense)

Location: Tustin, CA, US; onsite role

Salary: $163,000–$223,100 per year

Company

U.S.-based aerospace and defense technology company developing and producing mission-critical optical systems, precision coatings, and advanced laser subsystems for ISR&T, space, missile, and directed-energy applications.

What you will do

• Conceive and develop optical, mechanical, and opto-mechanical layouts, components, assemblies, and subsystems for airborne and space platforms.
• Lead product design and process-development initiatives, ensuring technical specifications and requirements are met.
• Create 3D solid models, drawings, procedures, work instructions, bills of materials, tooling designs, and assembly/testing procedures under document and configuration-control standards.
• Support Engineering, Program Management, Operations, Business Development, proposals, customer presentations, quotes, and program estimates.
• Resolve fabrication issues, perform root-cause evaluations, troubleshoot and test systems, and determine design manufacturability.
• Improve existing designs and processes while contributing to conceptual and R&D initiatives for emerging technologies.

Requirements

• Bachelor’s degree with 11+ years of experience, or a Master’s degree with 8–10+ years, or a Ph.D. with 4+ years in mechanical engineering or a related field.
• Strong understanding of optical and mechanical design principles and the ability to apply engineering theory.
• Significant CAD experience; SolidWorks is preferred.
• Experience designing optical systems for advanced light sources, including tolerance analysis, manufacturability, and cost considerations.
• Experience applying design-for-assembly and integration practices to complex opto-mechanical devices, including tolerance stack-up analysis.
• Knowledge of metal machining and optical fabrication processes, including grinding, polishing, coating, and testing.
• Understanding of thermal, mechanical, vibration, and shock effects on optical systems.
• Experience with optical alignment tools, metrology, assembly procedures, troubleshooting, testing, and analysis.
• Experience working with vendors and suppliers for optics, mechanical parts, tooling, and coatings.
• Must be a U.S. Person under applicable regulations or eligible for authorization under a U.S. government export license.

Nice to have

• Familiarity with FEA software, particularly Simcenter or FEMAP.
• Familiarity with materials for refractive systems across IR, SWIR, NIR, visible, and UV spectra, as well as mechanical substrates and coatings.
• Strong independent and team-based delivery, interpersonal, organizational, and communication skills.

Culture & Benefits

• Full-time position with responsibilities spanning engineering, program management, operations, manufacturing, testing, and business development.
• Equal opportunity and affirmative action employer; qualified applicants receive consideration without regard to protected characteristics.
• Salary offers are determined by responsibilities, experience, education, training, specialized skills, and market and business conditions.