Senior Fea Engineer Jobs in Reston, VA (NOW HIRING)

We are seeking a Senior Mechanical Analyst with deep expertise in structural and thermal analyses, environmental testing, and aerospace hardware development. As a Sr. Mechanical Analyst, you will support design development of complex laser and electro-optical systems for military and/or aerospace applications.

Duties include assessment of customer technical requirements and knowledge of environmental test standards. The responsibilities require full knowledge of military/aerospace design cycles and general design requirements and development of robust design solutions to meet laser performance specifications. Duties would also include creation and/or defeaturing of CAD models to be used for analyses, analyzing systems thermally and structurally, supporting assembly and testing of systems, preparing technical reports, and participating in design review meetings.

Essential Duties & Responsibilities: Analysis & Simulation Perform structural, thermal, and fatigue analysis of aerospace components and systems Conduct stress, vibration, and environmental analyses (launch loads, thermal vacuum, shock, etc.) Use tools such as ANSYS Mechanical for FEA analysis Environmental Testing & Validation Plan and support environmental testing (space and airborne conditions) Analyze test results and correlate with models Support qualification and verification efforts for high-reliability systems Design & CAD Modeling Develop 3D models and engineering drawings using Creo Perform analysis-driven design iterations Collaborate with cross-functional teams to ensure manufacturability and performance Technical Communication & Presentations Develop and deliver clear, concise presentations to both technical and executive audiences Lead customer-facing technical discussions and design reviews Communicate complex analysis results through well-structured slides and visualizations Collaboration & Execution Work with internal teams and external partners Demonstrate strong time management and prioritization across multiple projects Proactively seek feedback, ask questions, and collaborate effectivelyExperience & Expertise Required: Experience in the design and analysis of electro-optical systems for military and/or aerospace applications Bachelor's degree in Mechanical Engineering (or related field) with 10+ years of experience, or Master's degree with 7+ years of experience Strong background in: Thermal and structural analysis Stress and fatigue analysis Environmental testing (space or airborne systems preferred) Experience with: ANSYS Mechanical APDL or Workbench CAD modeling tools such as PTC Creo Ability to create and interpret engineering drawings and models Proven ability to present technical material clearly to diverse audiences Excellent problem-solving and communication skills Experience supporting spaceflight or satellite programs Familiarity with high-reliability (Hi-Rel) or defense systems Experience working with or alongside major aerospace organizations Knowledge of fatigue, fracture mechanics, and advanced materials behavior BS in Mechanical Engineering required, MS preferred 10 years relevant experience minimumExperience & Expertise Required: Experience in the design and analysis of electro-optical systems for military and/or aerospace applications Bachelor's degree in Mechanical Engineering (or related field) with 10+ years of experience, or Master's degree with 7+ years of experience Strong background in: Thermal and structural analysis Stress and fatigue analysis Environmental testing (space or airborne systems preferred) Experience with: ANSYS Mechanical APDL or Workbench CAD modeling tools such as PTC Creo Ability to create and interpret engineering drawings and models Proven ability to present technical material clearly to diverse audiences Excellent problem-solving and communication skills Experience supporting spaceflight or satellite programs Familiarity with high-reliability (Hi-Rel) or defense systems Experience working with or alongside major aerospace organizations Knowledge of fatigue, fracture mechanics, and advanced materials behavior BS in Mechanical Engineering required, MS preferred 10 years relevant experience minimum