Senior Staff Mechanical Engineer

CHAOS Industries is redefining modern defense with omniscient systems purpose-built for today’s realities. Designed and built by top U.S. military veterans and Silicon Valley innovators, CHAOS Industries’ products are powered by Coherent Distributed Networks (CDN™), empowering warfighters, commercial air operators, and border protection teams to act faster, adapt rapidly, and stay ahead of evolving threats. In a world where technological threats move at unprecedented speed, CHAOS Industries delivers advanced sensing and detection solutions that give the ultimate advantage: time.

CHAOS is seeking a Senior Staff Mechanical Engineer to lead the design, development, packaging, integration, and qualification of ruggedized electronic hardware, sensor systems, avionics, and related mission-critical hardware for dual-use aerospace and defense applications. The ideal candidate brings strong hands-on mechanical design and CAD expertise, experience with complex assemblies and integrated systems, demonstrated prototyping and analysis skills, and the ability to work effectively within cross-disciplinary teams spanning mechanical, electrical, RF, power, manufacturing, and systems engineering.

Design challenges may include structures, enclosures, mechanisms, electromechanical hardware, thermal solutions, support equipment, and other mission-critical systems. The position spans the product lifecycle from concept development and architecture through detailed design, analysis, prototyping, qualification testing, production, and sustainment of fielded systems.

This is a full-time, on-site position in El Segundo, CA.

• Lead the design, development, packaging, and mechanical integration of ruggedized electronic hardware, sensor systems, avionics, structures, mechanisms, and related support equipment

• Own mechanical design responsibility for a subsystem, product area, or hardware integration effort, ensuring alignment with system-level requirements, mission needs, and program constraints

• Develop mechanical architectures and detailed designs subject to structural, thermal, environmental, manufacturability, installation, and operational requirements

• Develop and maintain 3D CAD models, large assemblies, detailed drawings, installation documentation, and interface control documents (ICDs), ensuring production-ready quality and configuration control

• Perform first-order structural and thermal analyses, hand calculations, requirements analysis and allocation, and design verification activities

• Provide technical guidance during system integration, qualification, acceptance, fit-check, installation, alignment, and troubleshooting activities

• Serve as a key technical hardware interface with customers, suppliers, manufacturing partners, and other cross-functional stakeholders

• Perform make/buy assessments and support prototype fabrication, assembly, production transition, configuration control, and fielded system sustainment

• Provide technical and career mentoring to less-experienced engineers and designers

• Bachelor’s degree in Mechanical Engineering or a related discipline

• 10+ years of progressively responsible experience in mechanical design and integration of electronic hardware for aerospace, defense, or similar applications

• Strong proficiency with mechanical CAD tools, such as SolidWorks or equivalent, including complex assemblies and detailed design

• Experience producing and reviewing production-ready mechanical drawings and documentation

• Strong