CHAOS Industries is redefining modern defense with omniscient systems that give the ultimate advantage—domain dominance. CHAOS Industries’ products are powered by Coherent Distributed Networks (CDN™), empowering warfighters, commercial air operators, and border protection teams to act faster, adapt rapidly, and stay ahead of evolving threats.

CHAOS Industries was founded in 2022 and has raised a total of $1 billion in funding from leading investors, including 8VC, Accel, and Valor Equity Partners. The company is headquartered in Los Angeles, with offices in Washington, D.C., San Francisco, San Diego, Seattle, and London. For more information, please visit www.chaosinc.com.

Role Overview:

CHAOS is seeking a Senior Principal Mechanical Design Engineer to serve as the technical authority for the design, integration, and qualification of electronic hardware and enclosures for aerospace and defense applications. This role is responsible for setting mechanical direction across programs, solving complex design challenges, and ensuring technical excellence from concept through qualification, production, and sustainment.

The ideal candidate brings deep hands-on mechanical design expertise, strong CAD and packaging experience, and a proven ability to independently lead cross-disciplinary technical efforts spanning mechanical, electrical, RF, power, and systems engineering.

This is a full-time, on-site position in Hawthorne, CA.

Responsibilities:

• Architect and design ruggedized electronic hardware and enclosures, including chassis, card-level packaging, mounting features, and thermal solutions, in accordance with program requirements and applicable standards

• Define and maintain mechanical architectures, interfaces, and design approaches to support multi-disciplinary system integration.

• Develop and oversee 3D CAD models, assemblies, drawings, and interface control documentation (ICDs), ensuring production-ready quality and configuration control.

• Perform first-order structural and thermal analyses to support design decisions and verify compliance with environmental and performance requirements

• Perform and/or review first-order structural and thermal analyses to support design decisions and verify compliance with environmental and performance requirements

• Lead cross-disciplinary technical resolution involving mechanical, electrical, RF, power, and systems engineering teams

• Serve as a primary technical hardware interface with customers, platform providers, suppliers, and manufacturing partners.

• Perform make/buy assessments with manufacturing partners as required

• Support production transition, configuration control, and fielded system sustainment, including investigation and resolution of integration issues

Minimum Requirements:

• Bachelor’s degree in Mechanical Engineering or a related discipline

• 12+ years of progressively responsible experience in mechanical design and integration of electronic hardware for aerospace, defense, or similar applications

• Expert proficiency with mechanical CAD tools (e.g., SolidWorks or equivalent) and experience producing production-ready drawings

• Expertise in mechanical interfaces, tolerancing, alignment, installation practices, and interface control documents (ICDs)

• Familiarity with military and aerospace connectors (e.g., MIL-DTL-38999, ARINC, Micro-D)

• Strong understanding of mechanical drafting standards, GD&T, tolerance analysis, and configuration-controlled documentation

• Demonstrated experience with ruggedized military hardware and environmental qualification considerations

• Experience interpreting and applying military standards, such as MIL-STD-810 and related platform qualification requirements

• Proven ability to lead technical decisions and resolve complex, cross-disciplinary integration challenges

• Strong written and verbal communication skills and ability to operate effectively across multiple programs

• Ability to obtain and maintain a U.S. security clearance

Preferred Requirements:

• Master’s degree in Mechanical Engineering or a related field

• Prior experience serving as a mechanical technical authority on a program

• Experience with system-level requirements allocation and architecture trade studies

• Experience supporting environmental qualification testing and analysis (thermal cycling, vibration, shock)

• Experience with commercial FEA or multiphysics simulation tools (e.g., NASTRAN, ABAQUS, ANSYS, CFD codes, COMSOL, etc.)

• Familiarity with military and aerospace standards and specifications

• Experience supporting cable harness routing, connector layouts, and electromechanical integration

Why CHAOS?

• Health Benefits: Medical, dental, and vision benefits 100% paid for by the company
• Additional benefits: 401k (+ 50% company match up to 6% of pay), FSA, HSA, life insurance, and more
• Our Perks: Free daily lunch, ‘No meeting Fridays’, unlimited PTO, casual dress code
• Compensation Components: Competitive base salaries, generous pre-IPO stock option grants, relocation assistance, and (coming soon!) annual bonuses
• Team Growth: 200 employees and counting across 5 global offices

The stated compensation range reflects only the targeted base compensation range and excludes additional earnings such as bonus, equity, and benefits. If your compensation requirements fall outside of the range, we still encourage you to apply. The salary range for this role is an estimate based on a range of compensation factors, inclusive of base salary only. Actual salary offer may vary based on (but not limited to) work experience, education and/or training, critical skills, and/or business considerations.

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