Principal Mechanical Engineer (Opto-Mechanical

Principal Mechanical Engineer – Opto-Mechanical

Our mission is to push the boundaries of what is possible in mission-critical aerospace and defense systems. We develop advanced, AI-enabled solutions designed to operate in demanding space, airborne, and ground environments where performance, reliability, and precision are essential.

As a Principal Mechanical Engineer – Opto-Mechanical, you will serve as a technical leader responsible for the architecture, analysis, design, integration, and qualification of precision opto-mechanical systems. You will develop innovative mechanical solutions for complex electro-optical assemblies and provide technical leadership across the full product lifecycle—from concept development and requirements definition through detailed design, environmental qualification, production, fielding and support.

This role requires strong technical depth in opto-mechanical engineering, precision mechanisms, structural analysis, GD&T, thermal management, and design for harsh environments. You will lead engineering trade studies, make critical design decisions, resolve complex technical challenges, and collaborate closely with systems, optical, electrical, manufacturing, test, and program engineering teams.

In addition to direct technical contribution, you will mentor and develop engineers, designers, and technicians while helping shape engineering processes, technical strategy, and new business opportunities.

Essential Responsibilities

• Lead opto-mechanical design and development across multiple aerospace and defense programs from concept through production and field deployment.
• Develop precision mechanical architectures for electro-optical systems operating in space, airborne, and ground-based environments.
• Perform and lead engineering analyses to validate designs for structural integrity, stiffness, strength, vibration, shock, thermal performance, environmental durability, manufacturability, reliability, schedule, and cost.
• Lead technical trade studies involving structural configuration, materials, mechanisms, thermal management, tolerancing, manufacturability, and system-level performance.
• Develop technical requirements, specifications, concepts, preliminary and detailed designs, engineering analyses, test procedures, assembly procedures, and technical reports.
• Create, review, and approve technical data packages, including fabrication, assembly, interface, source-control, and configuration-controlled drawings, in accordance with ASME Y14.5 and applicable internal and customer standards.
• Apply advanced GD&T and tolerance analysis techniques to ensure optical alignment, mechanical interfaces, and system performance requirements are achieved.
• Specify, select, and integrate electromechanical actuators, precision mechanisms, bearings, flexures, and positioning components used for optical alignment and positioning.
• Conduct or oversee Finite Element Analysis (FEA) and other analytical methods to evaluate structural and mechanical performance.
• Support thermal analysis and thermal-mechanical design of electro-optical assemblies, including interfaces between optical, mechanical, and electronic components.
• Design for and evaluate performance in demanding environments, including vibration, shock, thermal cycling, temperature extremes, contamination, and other applicable aerospace environmental conditions.
• Apply knowledge of MIL-SPECs, MIL-STDs, aerospace standards, component qualification requirements, and component failure modes to product design and development.
• Support engineering development and qualification testing, including test planning, instrumentation, test readiness, data review, failure investigation, and corrective actions.
• Lead technical design reviews, including SRR, PDR, CDR, TRR, and other program milestone reviews, as applicable.
• Author and present technical material during internal, customer, and cross-functional design reviews.
• Proactively identify and mitigate technical, schedule, cost, manufacturing, and supply-chain risks throughout the product lifecycle.
• Work as a technical leader within an Integrated Product Team (IPT), coordinating across mechanical, optical, electrical, systems, manufacturing, quality, test, and program management functions.
• Provide technical mentorship and guidance to mechanical engineers, designers, and technicians, helping establish sound engineering practices and developing the next generation of technical talent.
• Support transition from engineering development to production through design-for-manufacturability, producibility, inspection, assembly, and configuration-management activities.
• Contribute technical content to cost, schedule, technical, and management volumes for proposals, bids, and new business opportunities.
• Support customer engagements and provide technical input to requirements development, solution definition

Qualifications

• Bachelor’s degree in Mechanical Engineering or higher.
• 7 years of experience in opto-mechanical design for aerospace, or defense systems.
• Advanced proficiency in SolidWorks or equivalent CAD tools and GD&T per ASME Y14.5.
• Proven experience developing Technical Data Packages, specifications, and conceptual designs.
• Experience in systems thinking including trade studies, analysis of alternatives, developing requirements .
• Strong understanding of DFM/DFA, material properties, tolerance analyses, and design‑to‑cost optimization and environmental qualification requirements.
• Experience in electro‑optic design or manufacturing environments.
• U.S. Person status required; eligibility for security clearance preferred.

Preferred Extras

• Experience with FEA and analysis tools in Solidworks.
• Experience with MIL‑STD‑810 testing (shock, vibration, thermal).
• Familiarity with optical‑mechanical alignment and precision mechanism design.
• Experience with PDM, and ERP or PLM systems for configuration and BOM control.

Why Clear Align

Clear Align is a leader in EO/IR imaging systems for mission-critical aerospace and defense applications. Our capabilities span sensor design and integration, optical fabrication, coatings, infrared and visible camera manufacturing, sensor integration, and AI-enabled video processing.

Clear Align is an equal opportunity employer.

Benefits:

• 401(k)
• 401(k) matching
• Dental insurance
• Employee assistance program
• Flexible schedule
• Flexible spending account
• Health insurance
• Life insurance
• Paid time off
• Parental leave
• Vision insurance

Education:

• Bachelor's (Required)

Experience:

• Opto-Mechanical : 5 years (Required)

Work Location: In person

Salary : $96,474 - $136,236