Staff Mechanical Engineer

About Dash 2 Dynamics (D2)

D2 is building a new class of advanced communications systems powered by the integration of plasma physics, radio-frequency engineering, and novel antenna architectures. Our work is aimed at overcoming fundamental limits in conventional antennas and enabling communications capabilities that are smaller, more wideband, and more resilient in demanding environments. We are taking breakthrough technology from the laboratory through rapid prototyping, rigorous modeling and test, product qualification, and operational deployment.

This is an opportunity to join a hands-on, multidisciplinary team working at the edge of electromagnetics, materials, electronics, plasma science, and mission-focused product development. The systems we are developing will reshape how defense, aerospace, and commercial users communicate across contested and congested RF environments.

About the Role

Dash 2 Dynamics (D2) is seeking a practical, inventive Staff Mechanical Engineer to serve as the senior mechanical technical owner for plasma-enabled antenna and advanced communications hardware. You will shape mechanical architecture, lead critical design trades, and drive antenna assemblies, plasma devices, electronics housings, fixtures for installation and platform integration, thermal interfaces, and test hardware from early concepts through qualification-ready designs, while raising engineering rigor across the team.

What You Will Do

Mechanical Architecture & Technical Leadership

Own the mechanical architecture for advanced antenna, plasma-device, electronics, and communications-system hardware.

Lead mechanical design reviews, establish analysis and documentation standards, and guide critical decisions involving performance, risk, cost, schedule, and manufacturability.

Define modular product architectures that can evolve from laboratory prototypes to fieldable systems and future product variants.

Mentor engineers and provide trusted technical guidance across multidisciplinary programs.

Detailed Design, Thermal & Structural Engineering

Create and maintain CAD models, production drawings, GD&T schemes, tolerance analyses, bills of material, and configuration-controlled design documentation.

Perform or direct thermal and structural analyses for electronics, antenna assemblies, plasma devices, and environmental loads.

Select materials and joining methods for high voltage, RF exposure, thermal cycling, vacuum or controlled environments, and rugged use.

Engineer interfaces involving ceramics, metals, seals, brazed or bonded joints, precision alignment, thermal expansion, shock, vibration, and fatigue.

Prototype, Test & Qualification

Drive rapid hardware iteration from concept through prototype, integration, environmental test, qualification, and design release.

Design fixtures and test articles; support instrumentation, assembly, troubleshooting, root-cause analysis, and corrective action.

Define test procedures and acceptance criteria that retire the highest mechanical risks and produce defensible design evidence.

Correlate thermal and structural predictions with measured hardware behavior and incorporate learning into subsequent designs.

Manufacturing & Supplier Execution

Apply DFM and DFA principles while preserving RF, plasma, thermal, structural, and serviceability requirements.

Lead technical engagement with machine shops, specialty joining and brazing vendors, additive manufacturers, and contract manufacturing partners.

Review quotes, supplier capabilities, first articles, inspection results, nonconformances, and corrective actions.

Establish repeatable assembly, inspection, quality, and configuration-management processes.

Qualifications

Required

Bachelor's degree in Mechanical Engineering, Aerospace Engineering, Materials Engineering, or a related field.

7+ years of relevant mechanical product-development experience, including technical ownership of complex electromechanical hardware through design, build, integration, and test.

Advanced proficiency with a modern 3D CAD platform, production drawings, GD&T, and tolerance analysis.

Strong command of thermal management, structural mechanics, materials selection, and manufacturing processes.

Demonstrated ability to lead design reviews, mentor engineers, communicate technical risk, and make sound decisions with incomplete information.

Hands-on experience with experimental hardware and disciplined technical documentation.

Ability to meet requirements associated with work on U.S. government and national-security programs.

Nice to Have

Experience with antenna systems, RF electronics packaging, aerospace hardware, high-voltage equipment, vacuum systems, or plasma devices.

Experience with ceramics, metal-ceramic interfaces, brazing, adhesives, seals, coatings, or high-temperature assemblies.

Proficiency with finite-element thermal or structural analysis and model-to-test correlation.

Experience supporting environmental qualification, including shock, vibration, temperature, ingress, or related testing.

Experience in an early-stage company, rapid-prototyping organization, defense program, or SBIR/STTR environment.

Active U.S. security clearance or eligibility to obtain one.

Salary Range: $145,000-$170,000. This represents the typical base salary range for this position based on experience, skills, and other factors.