Staff Mechanical Engineer

CHAOS Industries is redefining modern defense with a multi-product portfolio that gives the ultimate advantage—domain dominance. The company's 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.

CHAOS Industries was founded in 2022 and has raised a total of $1 billion in funding from leading investors, including 8VC, Accel, and Valor Equity Partners. The company is headquartered in Los Angeles, with offices in Washington, D.C., San Francisco, San Diego, Seattle, and London. For more information, please visit www.chaosinc.com.

CHAOS is seeking a Staff Mechanical Engineer to perform the hands-on design, development, packaging, integration, and qualification of ruggedized sensor systems, avionics, electronic hardware, and related mission-critical systems for dual-use aerospace and defense applications. The ideal candidate brings strong mechanical design and CAD expertise, experience with complex assemblies and integrated systems, and demonstrated prototyping, analysis, and problem-solving skills.

The position supports the product lifecycle from concept development and architecture through detailed design, analysis, prototyping, qualification testing, production, fielding, and sustainment. Design challenges may include structures, enclosures, mechanisms, electromechanical hardware, thermal solutions, support equipment, and other systems deployed across land-, sea-, and air-based platforms.

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

• Perform hands-on mechanical design and integration of ruggedized electronic hardware, sensor systems, avionics, structures, mechanisms, enclosures, and related support equipment

• Own the mechanical design and integration of defined subsystems, product areas, or major assemblies.

• Perform trade studies and recommend path forward

• Develop and maintain 3D CAD models, assemblies, detailed drawings, installation documentation, and interface control documents (ICDs)

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

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

• Lead design review on owned design

• Work collaboratively with mechanical, electrical, RF, power, manufacturing, systems engineering, customers, suppliers, and platform providers to resolve integration challenges

• Support system integration, qualification, fit-check, installation, alignment, troubleshooting, prototype fabrication, assembly, and transition to production

• Support configuration control, make/buy evaluations, fielding, and sustainment of deployed systems

• Mentor junior engineers

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

• 7+ 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

• Understanding of mechanical interfaces, tolerancing, alignment, installation practices, and interface control documents (ICDs)

• Familiarity with military and aerospace connectors, such as MIL-DTL-38999, ARINC, and Micro-D

• Understanding of mechanical drafting standards, GD&T, tolerance analysis, and