Principal 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 https://www.chaosinc.com. Role Overview:  CHAOS is seeking a Principal Mechanical Design Engineer to lead the mechanical design, integration, and qualification of electronic hardware and enclosures for aerospace and defense applications. The ideal candidate brings deep hands-on mechanical design expertise, strong CAD and packaging experience, and a proven ability to independently lead cross-disciplinary technical efforts spanning mechanical, electrical, RF, power, and systems engineering.  This is a full-time, on-site position in Hawthorne, CA.    Responsibilities:  Lead the design and development of ruggedized electronic hardware and enclosures, including chassis, card-level packaging, mounting features, and thermal solutions, in accordance with program requirements and applicable standards  Own mechanical design responsibility for a subsystem or product area, ensuring alignment with system-level requirements and program constraints  Develop and maintain 3D CAD models, assemblies, detailed drawings, and interface control documentation (ICDs), ensuring production-ready quality and configuration control  Perform first-order structural and thermal analyses to support design decisions and verify compliance with environmental and performance requirements  Drive cross-disciplinary technical resolution involving mechanical, electrical, RF, power, and systems engineering teams  Serve as a key technical interface with suppliers and manufacturing partners  Perform make/buy assessments with manufacturing partners as required  Support production transition, configuration control, and fielded system sustainment, including investigation and resolution of integration issues    Minimum Requirements:  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 (e.g., SolidWorks or equivalent) and experience producing production-ready drawings  Expertise in mechanical interfaces, tolerancing, alignment, installation practices, and interface control documents (ICDs)   Familiarity with military and aerospace connectors (e.g., MIL-DTL-38999, ARINC, Micro-D)  Strong understanding of mechanical drafting standards, GD&T, tolerance analysis, and configuration-controlled documentation  Demonstrated experience with ruggedized military hardware and environmental qualification considerations  Experience interpreting and applying military standards, such as MIL-STD-810 and related platform qualification requirements  Proven ability to lead technical decisions and resolve complex integration challenges  Strong written and verbal communication skills and ability to operate effectively in fast-paced, multi-disciplinary development environments  Ability to obtain and maintain a U.S. security clearance    Preferred Requirements:  Master’s degree in Mechanical Engineering or a related field  Prior experience serving as a lead mechanical engineer on a program  Experience with system-level requirements allocation and architecture trade studies  Experience supporting environmental qualification testing and analysis (thermal cycling, vibration, shock)  Experience with commercial FEA or multiphysics simulation tools (e.g., NASTRAN, ABAQUS, ANSYS, CFD codes, COMSOL, etc.)  Familiarity with military and aerospace standards and specifications  Experience supporting cable harness routing, connector layouts, and electromechanical integration  Experience supporting prototype fabrication, assembly, and transition to production  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 $170k-240k 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.    Recruiting Agencies: CHAOS Industries does not accept unsolicited resumes or outreach. Unsolicited submissions will not be reviewed or compensated.   #LI-onsite Offices: Los Angeles, California, United States (Los Angeles, CA);