Senior Mechanical Engineer

CHAOS Industries is redefining modern defense with a multi-product portfolio that gives the ultimate advantagedomain dominance. The companys 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 .

Role Overview:

CHAOS is seeking a Senior Mechanical Engineer to support 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 spans 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.

Responsibilities:

• Design ruggedized electronic hardware sensor systems avionics enclosures structures mechanisms and related support equipment in accordance with program requirements and applicable standards
• Develop and maintain 3D CAD models complex assemblies detailed drawings installation documentation and interface control documents (ICDs)
• Own the design and documentation of assigned components assemblies and mechanical subsystems
• Track and manage size weight and mechanical allocations for electronic assemblies and integrated hardware
• Perform first-order structural and thermal analyses hand calculations requirements analysis and design verification activities
• Support prototype fabrication assembly mechanical integration testing qualification fit-check installation alignment and troubleshooting activities
• Collaborate with mechanical electrical RF power manufacturing systems engineering customers suppliers and platform providers to resolve integration challenges
• Support make/buy evaluations production transition Design for Manufacturing and Assembly (DFMA) configuration control fielding and sustainment activities
• Participate in design reviews failure investigations and other technical decision-making activities

Minimum Requirements:

• Bachelors degree in Mechanical Engineering or a related discipline
• 4 years of relevant 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 parts and assemblies
• Experience producing and reviewing production-ready mechanical drawings and documentation
• Understanding of mechanical interfaces tolerancing alignment installation practices GD&T tolerance analysis and configuration-controlled documentation
• Experience designing or integrating mechanical hardware for RF avionics power electronics embedded computing or similar products
• Familiarity with structural analysis methods including hand calculations and FEA
• Experience supporting prototype builds integration testing or qualification activities
• Familiarity with ruggedized hardware and applicable environmental requirements
• Strong problem-solving skills attention to detail and ability to work effectively in fast-paced multi-disciplinary development environments
• Ability to obtain and maintain a U.S. security clearance

Preferred Requirements:

• Masters degree in Mechanical Engineering or a related field
• Experience supporting environmental qualification testing and analysis including thermal cycling vibration and shock
• Experience with commercial FEA or multiphysics simulation tools such as NASTRAN ABAQUS ANSYS COMSOL or similar tools
• Familiarity with military and aerospace standards including MIL-STD-810
• Familiarity with military and aerospace connectors such as MIL-DTL-38999 ARINC and Micro-D
• Experience with mechanisms actuation systems structures thermal management packaging cable routing connector layouts or electromechanical integration
• Experience with additive manufacturing CNC machining fabrication assembly and prototype development
• Hands-on experience working with machine shop and prototype lab equipment

Why CHAOS

• Health Benefits: Medical dental and vision benefits 100% paid for by the company
• Additional benefits: 401k ( 50% company match up to 6% of pay) FSA HSA life insurance and more
• Our Perks: Free daily lunch No meeting Fridays unlimited PTO casual dress code
• Compensation Components: Competitive base salaries generous pre-IPO stock option grants relocation assistance and (coming soon!) annual bonuses
• Team Growth: 250 employees and counting across 5 global offices

The stated compensation range reflects only the targeted base compensation range and excludes additional earnings such as bonus equity and benefits. If your compensation requirements fall outside of the range we still encourage you to apply. The salary range for this role is an estimate based on a range of compensation factors inclusive of base salary only. Actual salary offer may vary based on (but not limited to) work experience education and/or training critical skills and/or business considerations.

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