Senior Mechanical Engineer – Optomechanical Systems

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About The Role

Physical Sciences Inc. (PSI) is an employee-owned company located just north of Boston in Andover, MA. PSI is seeking an experienced, innovative Senior Mechanical Engineer to join our collaborative, multidisciplinary team. In this role, you will lead the research, design, and development of next-generation mechanical and optomechanical systems for energy, aerospace, and defense applications.

This position offers a unique opportunity to contribute to cutting-edge technologies for national security programs. The ideal candidate will have a proven track record of designing, analyzing, and fabricating advanced prototypes that integrate complex optical and electronic subassemblies, successfully driving novel research initiatives toward commercialization.

What You’ll Do

• Lead System Development: Oversee the complete design, analysis, and development of mechanical systems, including structural components, rugged enclosures, precision mechanisms, and robust thermal management solutions.
• Advance Materials Research: Conduct targeted research into advanced materials, lightweight structures, and novel manufacturing processes to optimize system performance and structural reliability.
• Integrate Optomechanics: Seamlessly import Zemax designs into 3D CAD environments to develop fully integrated, high-precision optomechanical systems.
• Generate Technical Documentation: Create robust CAD models, detailed engineering drawings, and comprehensive technical documentation in strict accordance with ASME and MIL standards.
• Prototyping & Validation: Perform hands-on prototype assembly, environmental testing, and experimental validation of coupled electrical and optomechanical behaviors.
• Collaborate Across Disciplines: Work seamlessly within cross-functional teams that include mechanical, electrical, materials, and systems engineers, as well as chemists, physicists, and manufacturing specialists to meet strict industry performance and compliance standards.
  
  

Qualifications & Requirements

• Education: Master’s degree in Mechanical Engineering or a closely related engineering discipline.
• Experience: 5 years of hands-on mechanical design experience specifically within a fast-paced research and development (R&D) environment.
• Technical Mastery: Exceptional proficiency in 3D CAD tools (SolidWorks expertise is highly preferred).
• Materials & Manufacturing: Strong knowledge of materials (metals, high-temperature alloys, composites) and diverse manufacturing methodologies (machining, casting, forging, additive manufacturing).
• Analysis Tools: Skilled in using advanced simulation software such as ANSYS, Abaqus, NASTRAN, or MATLAB.
• Standards Compliance: Familiarity with aerospace/defense design standards, MIL-STD specifications, ITAR regulations, and design-for-reliability principles.
• Some experience with hypersonics and thermal protection systems (TPS).
• Security Clearance: Due to the nature of our national security programs, U.S. Citizenship is required, along with the active holding of or the ability to obtain a U.S. DoD Security Clearance (Secret or higher).
  
  

Additional Information

• U.S. Citizenship is required.
• PSI is proud to be an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, disability, or veteran status.
  
  

Pay Range: The estimated annual base salary range for this role is $100K–$140K. The actual salary offered will depend on the candidate’s experience, education, and specialized skills.