Associate Mechanical Design Engineer

This position may be located in O'Fallon, MO, Indianapolis, IN, or Frederick, MD

Bascom Hunter is an advanced technology and product development company specializing in aerospace, defense, and other high-performance electromechanical systems. We develop innovative products for military and commercial customers from concept through production.

The Associate Mechanical Design Engineer supports the design, analysis, development, and qualification of mechanical and electromechanical products. Working under the guidance of senior engineers, this role contributes throughout the product development lifecycle, including concept development, detailed design, prototype fabrication, testing, qualification, and production support.

This position provides an excellent opportunity to develop technical expertise while working on complex aerospace and defense hardware in a collaborative, multidisciplinary engineering environment.

Responsibilities

Mechanical Design

• Develop 3D CAD models, assemblies, and manufacturing drawings using SolidWorks.
• Design mechanical components, electronic enclosures, brackets, structural hardware, sheet metal, machined parts, and electromechanical assemblies.
• Support engineering trade studies and product development activities.
• Develop tolerance stack-ups, mechanical interfaces, and assembly concepts.

Engineering Analysis

• Perform engineering calculations and assist with structural, thermal, and vibration analysis using hand calculations and FEA tools.
• Support evaluation of stress, fatigue, thermal effects, and structural performance.
• Assist with material selection, fastener design, and environmental sealing solutions.

Product Development

• Support all phases of product development, including concept development, detailed design, prototype fabrication, qualification testing, and production transition.
• Prepare engineering documentation, manufacturing drawings, and bills of material.
• Participate in design reviews and Engineering Change Notice (ECN) activities.

Systems Integration & Testing

• Support the mechanical integration of electronic assemblies, wiring, connectors, and mechanical hardware.
• Assist with prototype assembly, laboratory testing, troubleshooting, and data collection.
• Support environmental qualification activities, including vibration, thermal, shock, and durability testing.

Manufacturing Support

• Collaborate with Manufacturing, Test, Quality, and Supply Chain to resolve design and production issues.
• Incorporate Design for Manufacturability (DFM) and Design for Assembly (DFA) principles into new designs.
• Support prototype and production builds as required.

Required Qualifications

• Bachelor's degree in Mechanical Engineering.
• 1–5 years of mechanical design experience through internships, co-ops, or professional employment.
• Experience with SolidWorks or comparable 3D CAD software.
• Fundamental understanding of mechanics of materials, machine design, manufacturing processes, and engineering drawings.
• Familiarity with ASME Y14.5 Geometric Dimensioning and Tolerancing (GD&T).
• Strong analytical, organizational, and problem-solving skills.
• Effective written and verbal communication skills.
• U.S. Citizenship required.

Preferred Qualifications

• Experience with ANSYS Mechanical or other FEA software.
• Experience developing aerospace, defense, industrial, automotive, or other high-reliability products.
• Familiarity with MIL-STD-810, DO-160, or similar military or aerospace standards.
• Hands-on experience with prototype fabrication, testing, or laboratory work.
• Internship or professional experience supporting product development or manufacturing.

Desired Characteristics

• Strong mechanical aptitude and eagerness to learn.
• Hands-on approach to engineering and product development.
• Ability to manage multiple assignments in a fast-paced engineering environment.
• Effective collaborator with a commitment to quality and continuous improvement.
• Desire to develop into a technical leader through increasing engineering responsibility.

Why Bascom Hunter?

At Bascom Hunter, Associate Mechanical Design Engineers work alongside experienced engineers developing advanced aerospace and defense products. You'll gain hands-on experience across the complete product development lifecycle while building the technical foundation needed to advance into increasingly complex design and technical leadership roles.

Additional Information

All positions at Bascom Hunter are subject to background investigations. Employment is contingent upon successful completion of a background investigation including criminal history and identity verification.

Bascom Hunter is an Equal Opportunity Employer and complies with all applicable federal, state, and local employment laws.