Senior Mechanical Engineer - Structural/Thermal Analysis

Job Description
Job Description:
We are seeking an experienced Mechanical Engineer with strong skills in structural analysis, thermal analysis, and finite element analysis (FEA) to support a wide range of products across the BAE Systems Aerospace and Mission Systems segment. This is a full‑time analysis position focused on structural and thermal modeling, simulation, and engineering assessment. This role supports multiple business areas and includes work on electronics, EO/IR systems, RF components, precision mechanisms, and mission‑critical hardware.

As part of the Mechanical Analysis Capability Group, you will join a cross‑sector team of full‑time analysts who apply advanced engineering and simulation methods to understand, model, and predict mechanical behavior across diverse product lines. Senior candidates will provide technical leadership for complex analysis challenges and influence early architecture and major design decisions. Candidates who enjoy hands‑on analysis, modeling, and practical engineering judgment will excel in this role.

Key Responsibilities:

• Provide expert‑level technical leadership for complex structural and thermal analysis challenges, influencing early architecture and major design decisions.
• Define analysis objectives and approaches for ambiguous or first‑of‑kind technical problems with minimal guidance.
• Perform structural and thermal analyses using both classical engineering methods and industry‑standard FEA tools.
• Create and post‑process finite element models from component‑level to system‑level using tools such as Siemens Simcenter 3D/NX, NASTRAN, Ansys Mechanical, and Ansys Icepak.
• Execute modal, vibration, shock, static, steady‑state, and transient thermal analyses.
• Collaborate with multidisciplinary design teams to optimize system performance, reliability, and manufacturability.
• Lead analysis planning and technical reviews; mentor and guide junior engineers across programs.
• Communicate analysis results, technical recommendations, and risk assessments to internal and external stakeholders.
• Support program execution both onsite and remotely. This is a Hybrid role that requires at least 50% onsite presence.

Required Education, Experience, & Skills

• Bachelor’s Degree in Mechanical or Aerospace Engineering and 8+ years of relevant experience
• Demonstrated experience in FEA, modal and vibration analysis, shock, and static analysis of structures
• Experience performing steady-state and transient heat transfer modeling
• Ability to simplify complex problems into efficient analysis approaches that provide clear, actionable feedback.
• Strong communication skills and ability to work effectively in both onsite and remote team environments.
• Eligibility to obtain a DoD Security Clearance at the “Secret” level

Preferred Education, Experience, & Skills

• Master’s Degree in Mechanical or Aerospace Engineering and 8+ years of relevant experience.
• Experience with industry standard pre/post processors such as Simcenter 3D, Femap, ANSYS Workbench, ANSYS Mechanical, Hypermesh, etc.
• Experience with solvers such as NASTRAN, Abaqus, ANSYS, LS-Dyna, RADIOSS, Optistruct, etc.
• Knowledge of structural and thermal design of electronics
• Familiarity with composite materials and printed circuit board technologies
• Experience evaluating structural fatigue and solder joint reliability (creep, vibration fatigue, shock).
• Familiarity with STOP analysis (Structural, Thermal, Optical Performance) using tools such as SigFit
• Active Secret clearance.

Pay Information
Full-Time Salary Range: $132962 - $226035

Please note: This range is based on our market pay structures. However, individual salaries are determined by a variety of factors including, but not limited to: business considerations, local market conditions, and internal equity, as well as candidate qualifications, such as skills, education, and experience.

Employee Benefits: At BAE Systems, we support our employees in all aspects of their life, including their health and financial well-being. Regular employees scheduled to work 20+ hours per week are offered: health, dental, and vision insurance; health savings accounts; a 401(k) savings plan; disability coverage; and life and accident insurance. We also have an employee assistance program, a legal plan, and other perks including discounts on things like home, auto, and pet insurance. Our leave programs include paid time off, paid holidays, as well as other types of leave, including paid parental, military, bereavement, and any applicable federal and state sick leave. Employees may participate in the company recognition program to receive monetary or non-monetary recognition awards. Other incentives may be available based on position level and/or job specifics.


About BAE Systems, Inc.
BAE Systems, Inc. is a defense, aerospace, and security company headquartered in Falls Church, Virginia, with more than 40,000 employees worldwide. We serve, supply, and protect those who protect us. As one of the most geographically diverse international defense companies, we deliver a full range of products and services spanning air, land, maritime, space, and cyber, including advanced electronics, intelligence solutions, and dedicated customer support.

Our culture is performance-driven and values-led, built on curiosity, creativity, and collaboration. Purpose isn't a tagline here. It's what drives us. We're developing breakthrough technologies that defend national security and make a lasting impact on our communities and our planet. When you join BAE Systems, you're not just building a career. You're contributing to a mission that truly matters.

This position will be posted for at least 5 calendar days. The posting will remain active until the position is filled, or a qualified pool of candidates is identified.