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Mechanical Engineer – Research & Design

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Physical Sciences Inc. (PSI) is an employee-owned company located just north of Boston in Andover, MA. We are seeking an experienced Mechanical Engineer with 5–10 years of experience in research and design for energy, aerospace, and defense applications. The ideal candidate will bring expertise in developing innovative mechanical systems, structures, and components that meet the rigorous performance, safety, and compliance requirements of the aerospace and defense industry. This role offers the opportunity to contribute to cutting-edge technologies and national security programs in a collaborative, multidisciplinary environment.

Key Responsibilities

  • Lead the design, analysis, and development of aerospace and defense mechanical systems, including structural components, enclosures, mechanisms, and thermal management solutions.
  • Conduct research into advanced materials, lightweight structures, and manufacturing processes to optimize system performance and reliability.
  • Develop CAD models, detailed engineering drawings, and technical documentation in accordance with ASME and MIL standards.
  • Perform engineering analyses such as structural (FEA), thermal, vibration, shock, fatigue, and fluid dynamics simulations.
  • Prototype, test, and validate mechanical designs under conditions representative of aerospace and defense environments.
  • Collaborate with cross-functional teams including systems engineering, electrical, materials, chemistry, and manufacturing.
  • Ensure designs comply with applicable aerospace/defense standards, including MIL-STD, ASME, and ITAR requirements.
  • Support failure investigations, root cause analyses, and corrective actions.
  • Mentor junior engineers and contribute technical expertise in design reviews.
  • Contribute to business capture and proposal development for research extending from ongoing efforts

Qualifications

  • Bachelor’s or Master’s degree in Mechanical Engineering (or related discipline).
  • 5–10 years of experience in mechanical design within a research and development environment.
  • Proficiency in 3D CAD tools, expertise with SolidWorks a plus
  • Strong knowledge of aerospace materials (metals, composites, high-temperature alloys) and manufacturing methods (casting, forging, machining, additive manufacturing).
  • Hands-on experience with prototyping, environmental testing, and qualification processes.
  • Skilled in analysis tools such as ANSYS, Abaqus, NASTRAN, or MATLAB.
  • Familiarity with aerospace design standards, MIL-STD specifications, and design-for-reliability principles.

Preferred Skills 

  • Experience with hypersonics, propulsion systems, or thermal protection systems.
  • Experience with additive manufacturing or advanced materials.
  • Background in UAVs, spacecraft, or military ground/air systems.
  • Knowledge of defense acquisition processes and compliance frameworks.
  • Demonstrated contributions to patents, publications, or advanced aerospace research programs.
  • Active or 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.

For a list of company benefits, visit PSI benefits