Structural and Thermal Design and Test Engineer

Job Description

Thank you for your interest in BAE Systems! This opening is included as part of our November 2026 Aerospace & Mission Systems (AMS) Engineering Hiring Event. While we encourage all interested professionals to apply, please note that this is a selection-based interview event for candidates whose skills and experience match our hiring needs. If your background and skill set match these needs, we will reach out with next steps. If selected for an interview, specific opportunities based on your interests, experience, and skill set will be discussed with the hiring team. For candidates not local to the Cedar Rapids area, virtual interviews will be accommodated

You don’t see it, but it’s there. Our employees work on the world’s most advanced electronics – from saving emissions in the City of Lights to powering the Mars Rover to protecting the F 35 fighter jet. At Electronic Systems, you’ll be among the brightest minds, working on the aerospace and defense industry’s most difficult problems. Drawing strength from our differences, we’re innovating for the future. And you can, too. Our flexible work environment provides you a chance to change the world without giving up your personal life. We put our customers first – exemplified by our missions: “We Protect Those Who Protect Us®” and “We Innovate For Those Who Move The WorldTM.” Sound like a team you want to be a part of? Come build your career with BAE Systems.

In Precision Strike & Sensing Solutions, we design and manufacture state-of-the-art systems and technology that enable our customers to execute their precision strike missions.

BAE Systems is seeking a Senior Mechanical Engineer specializing in Thermal and Structural Design and Test. This role is critical to the physical validation and reliability of complex hardware, ensuring that components and assemblies can withstand all anticipated operational and environmental loads—including static, dynamic, heat transfer, and environmental stresses—without failure.

Unlike a pure analysis role, this position bridges the gap between design and physical verification. The successful candidate will be responsible for the mechanical architecture and structural/thermal integrity of hardware while directly overseeing environmental lab activities. This includes the operation of vibration shaker tables and temperature chambers, as well as the development of customized test profiles to simulate real-world operational environments.

The engineer will serve as a key technical resource, mentoring hardware engineering teams in structural and thermal design best practices and coordinating the execution of comprehensive temperature and vibration test efforts.

Key Responsibilities

Environmental Test Oversight & Execution

• Lead and oversee environmental lab activities, including the operation of vibration shaker tables and temperature/humidity chambers.

• Develop and create customized temperature and vibration profiles designed to simulate real-world operational environments and military specifications.

• Coordinate and execute temperature and vibration test efforts to validate hardware performance and design requirements.

• Develop customized thermal and dynamic test environments (fixtures, mounting, and instrumentation) to ensure accurate data collection.

Mechanical Design & Integrity

• Drive the mechanical architecture, structural integrity, and thermal stability of complex hardware and assemblies.

• Ensure all hardware is designed to withstand operational loads, including static, dynamic, and environmental stresses.

• Perform necessary thermal and structural analyses to support design decisions, validate design margins, and predict potential failure modes.

Cross-Functional Collaboration

• Act as a mentor to Hardware Engineering Teams, providing guidance on structural and thermal design best practices to improve first-pass success rates.

• Establish guidelines for physical validation and design-for-test (DFT) principles across projects.

• Collaborate closely with Hardware Engineering, System Engineering, and Program Management teams to ensure mechanical constraints are integrated into the overall system design.

Required Education, Experience, & Skills

• Bachelor’s degree in Mechanical Engineering.

• 3+ years of experience in mechanical engineering, with a strong emphasis on physical testing and hardware validation.

• Strong understanding of structural design best practices and the ability to apply them to complex hardware assemblies.

• Familiarity with heat transfer and structural mechanics principles to support design and validation efforts.

• A motivated self-starter capable of troubleshooting test failures and implementing corrective design actions.

• Strong written and verbal communication skills for documenting test results and presenting findings to leadership.

Preferred Education, Experience, & Skills

• Proven experience in the operation and management of environmental test equipment (vibration shakers, thermal chambers).

• Hands-on experience developing and executing temperature and vibration test plans.

• Ability to develop custom test fixtures and environments for dynamic and thermal validation.

Pay Information
Full-Time Salary Range: $88189 - $149922

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.