Senior Sustaining Engineer

Leads the mechanical design of electro‑optical (EO) systems and opto‑mechanical assemblies from concept through production. Designs major components or major portions of a functional system to develop or improve products and facilitate manufacturing operations. Translates customer and market requirements into robust mechanical architectures, balancing performance, manufacturability, cost targets, and configuration control. Utilizes CAD/PLM tools to create detailed models, drawings, and documentation; performs mechanical and thermal analyses; and works as a cross‑functional liaison to ensure seamless system integration and production readiness.

Responsibilities and Tasks:

• Own the mechanical architecture and design of electro‑optical enclosures, precision mounts, thermal frames, seals, and structural elements. Ensure optical alignment stability, thermal management, EMI/ESD robustness, and environmental durability.
• Create 3D CAD models, detailed drawings, and engineering documentation per internal standards (Creo Parametric preferred; Windchill PLM).
• Generate system‑level mechanical layouts and thoroughly detailed component designs with minimal supervision. Perform component‑level and assembly‑level tolerance analyses and stack‑ups to guarantee fit, function, and alignment.
• Analyze and optimize designs using structural (FEA) and thermal simulations (Ansys or Creo Simulation), material selection, finishes, and fabrication processes to meet performance and reliability goals. Translate CTQs into tolerance budgets and verify with analytical stack‑ups and build data.
• Design for manufacturing and cost: apply DFM/DFA and Design‑to‑Unit‑Production‑Cost (DTUPC) principles. Partner with manufacturing engineering to design or revise tooling, fixtures, and assembly methods.
• Document Critical‑to‑Quality (CTQ) characteristics for purchased parts and assemblies. Define drawing GD&T, datum strategies, and tolerance budgets; review supplier capability (Cp/Cpk) against key stacks and support first articles/production approval readiness.
• Prepare for and lead/contribute to design reviews (internal and external), risk assessments (DFMEA/PFMEA), and reliability planning; participate in peer reviews of complex mechanical approaches. Present tolerance budgets, key stack‑ups, and inspection plans.
• Prototype, assemble, and debug early units; support fabrication, inspection, and iterative refinement; assist production during initial builds and resolve build issues rapidly. Measure critical dimensions and update drawings/processes to close gaps.
• Integrate cross‑functionally with Project Engineering Managers (PEMs), Systems Engineers (SEs), Technical Product Managers (TPMs), Supply Chain, external Vendors, and Program Managers (PMs) to align requirements, schedules, budgets, and trade‑offs through NPI gates (e.g., SRR/PDR/CDR/TRR) and into production.
• Capture voice of the customer and apply Human Factors principles to improve usability, serviceability, and safety. Ensure compliance with applicable standards and company policies (e.g., GD&T per ASME, product safety, environmental test methods, configuration control).

Education, Experience/Knowledge & License/Certification:

• BS in Mechanical Engineering (or related field) and 6+ years product/tool design experience with CAD tools (preferably Creo Parametric with Windchill); or MS in ME and 3+ years relevant experience.
• CAD/PLM: Parametric modeling per best practices (Creo preferred); Windchill PLM; surfacing and mechanism design experience a plus.
• Analysis: Structural FEA (Ansys or Creo) and thermal analysis experience.
• Standards & methods: Advanced GD&T per ASME standards; complex tolerance analysis; DFM/DFA; DTUPC.
• Manufacturing knowledge: Machining, sheet metal, injection molding, adhesives/sealants, and additive manufacturing (3D printing a plus).
• Systems integration: Experience with sensors, imaging modules, fiber‑optic or opto‑electronic subassemblies, and EMI/ESD practices.
• Cross‑functional collaboration: Demonstrated success partnering with PEMs, SEs, TPMs, Supply Chain, Vendors, and PMs to drive requirements definition, risk mitigation, schedule/cost trade‑offs, and production readiness.
• Tools: Proficiency with MS Office (Outlook, Word, Excel, PowerPoint).
• Clearance: Must be able to obtain a U.S. Secret Clearance.
• Training pre‑requisites (within one year of taking position): ESD; Safety Training as dictated by the Safety Department

Skills and Abilities:

• 3D Modeling tools (Creo Parametric preferred; experience with SolidWorks/NX/Catia acceptable).
• 3D engineering analysis tools (Ansys, Creo Simulation).
• Microsoft Office, including Excel for engineering calculations and documentation.

• Occasional travel up to 10%.
• Ability to work in lab and production areas, use PPE as required, and lift up to 25 lbs.

#Onsite

#LI-AZ1 Why Roanoke, Virginia?

• Lower cost of living
• Family-friendly area
• Career and economic growth
• Scenic beauty
• Outdoor enthusiast's dream

• Most locations offer a 9/80 schedule, providing every other Friday off
• Competitive compensation & 401(k) program to plan for your future
• Robust medical, dental, vision, & disability coverage with qualified wellness discounts
• Basic Life Insurance and Additional Life & AD&D Insurances are available
• Flexible Vacation & PTO
• Paid Parental Leave
• Generous Employee Referral Program
• Voluntary Benefits Available: Longer Term Care, Legal, Identity Theft, Pet Insurance, and more
• Voluntary Tricare Supplement available for military retirees

*** If you encounter issues with your application, please email TalentAcquisition@ElbitAmerica.com ***