Direct Energy Jobs in Alabama (NOW HIRING)

Senior Mechanical Engineer

Huntsville, Alabama

Full Time

EO Solutions is a rapidly growing aerospace and defense company focused on advancing capabilities in Space Domain Awareness and Directed Energy Systems. Our teams work across Hawaii, Nevada, Alabama, and remote locations to solve critical national security challenges with innovative, mission‑focused technologies.

EO Solutions is seeking a highly skilled Senior Mechanical Engineer to support the architecture development, design, integration, and testing of advanced mechanical systems for High Energy Laser (HEL) weapon systems. This position will focus on the development of complex mechanical hardware including precision structures, thermal management systems, ruggedized enclosures, beam director support hardware, payload packaging, motion systems, and environmentally hardened deployable subsystems. The ideal candidate will possess strong mechanical engineering fundamentals, hands‑on development experience, and the ability to lead technical efforts from concept through deployment. The successful candidate will lead technical development efforts from concept through prototype, integration, test, and deployment while collaborating across multidisciplinary engineering teams.

• Lead the architecture development, design, analysis, integration, and testing of complex mechanical systems for High Energy Laser weapon systems
• Design and develop ruggedized precision mechanical hardware for Department of War applications
• Develop mechanical structures, mounts, enclosures, thermal management systems, and precision assemblies
• Perform structural, thermal, vibration, shock, and tolerance analyses for mission‑critical hardware
• Develop packaging solutions optimized for size, weight, power, cooling, and maintainability constraints
• Support mechanical integration of optical, electrical, and controls subsystems
• Develop detailed engineering drawings, 3D models, assembly documentation, and technical data packages
• Support prototype fabrication, hardware integration, troubleshooting, and qualification testing activities
• Conduct trade studies and support system architecture development efforts
• Collaborate with multidisciplinary engineering teams throughout system development lifecycle
• Support environmental qualification efforts and compliance with military and aerospace standards
• Participate in design reviews, customer technical interchange meetings, and technical planning activities
• Mentor junior mechanical engineers and provide technical leadership across development efforts
• Contribute to proposal efforts, technical planning, and architecture discussions as needed

• Bachelor’s degree in Mechanical Engineering or related technical discipline
• 8+ years of experience in mechanical engineering or hardware development
• Strong experience designing and integrating complex mechanical systems for aerospace, defense, or ruggedized applications
• Experience supporting full lifecycle hardware development from concept through integration and test
• Proficiency with CAD tools such as SolidWorks, Creo, or similar mechanical design software
• Experience performing structural, thermal, and mechanical analysis
• Familiarity with vibration, shock, thermal, and environmental design considerations
• Experience with precision mechanical assemblies and tolerance analysis
• Experience supporting hardware integration, test, troubleshooting, and verification activities
• Strong understanding of manufacturing processes, materials selection, and producibility considerations
• Ability to develop detailed engineering documentation and technical data packages
• Strong analytical, troubleshooting, and problem‑solving skills
• Strong written and verbal communication skills
• Ability to work effectively in fast‑paced multidisciplinary engineering teams
• Ability to obtain and maintain a U.S. security clearance

• Master’s degree in Mechanical Engineering or related discipline
• Active Secret or Top Secret clearance
• Experience designing and developing High Energy Laser (HEL), Directed Energy, or advanced weapon systems
• Experience with thermal management systems for high‑power electronics or laser systems
• Experience supporting airborne, tactical, or mobile defense platforms
• Familiarity with finite element analysis (FEA) tools such as ANSYS or NASTRAN
• Experience with precision motion systems, gimbals, or stabilized platforms
• Familiarity with military environmental standards and qualification testing
• Experience supporting rapid prototyping and transition to production efforts
• Experience working within integrated product teams supporting complex system development

• Strong systems‑thinking mindset with attention to engineering detail
• Ability to lead complex hardware development efforts from concept to deployment
• Comfortable operating in rapid development and prototyping environments
• Strong collaboration and technical leadership capabilities
• Ability to mentor junior engineers and contribute to engineering process improvement
• Mission‑focused mindset with a commitment to engineering excellence