Avionics Mechanical Packaging Engineer

We’re ALTEN Technology USA, an engineering company helping clients bring groundbreaking ideas to life—from advancing space exploration and life-saving medical devices to building autonomous electric vehicles. With 3,000+ experts across North America, we partner with leading companies in aerospace, medical devices, robotics, automotive, commercial vehicles, EVs, rail, and more.

As part of the global ALTEN Group—57,000+ engineers in 30 countries—we deliver across the entire product development cycle, from consulting to full project outsourcing.

When you join ALTEN Technology USA, you’ll collaborate on some of the world’s toughest engineering challenges, supported by mentorship, career growth opportunities, and comprehensive benefits. We take pride in fostering a culture where employees feel valued, supported, and inspired to grow.

The Avionics Mechanical Packaging Engineer applies advanced mechanical engineering techniques to design, analyze, and optimize avionics modules for UAS, and aerospace platforms. This role emphasizes SWaP (Size, Weight, and Power) optimization, PCBA and module packaging, and the development of ruggedized, lightweight enclosures that meet stringent aerospace environmental and manufacturing requirements. The engineer will lead or support packaging design efforts from concept through production, ensuring designs are reliable, manufacturable, and compliant with mission needs.

Position Responsibilities

• Lead or support mechanical packaging development for avionics modules, including PCBA sizing, layout, and integration into compact enclosures.

• Optimize SWaP trade-offs while balancing performance, reliability, and thermal constraints.

• Develop detailed 3D CAD models and mechanical drawings for PCBA carriers, connectors, housings, and avionics enclosures.

• Apply Design for Manufacturing (DFM), Design for Assembly (DFA), and Design for Test (DFT) principles to ensure cost-effective, scalable production.

• Support mechanical stress, vibration, and thermal analyses to validate avionics packaging designs.

• Collaborate with electrical and systems engineers to ensure mechanical designs integrate seamlessly with PCBAs, connectors, harnessing, and system interfaces.

• Define and manage dimensional tolerances, stack-ups, and mechanical interfaces for avionics modules.

• Support prototype builds, press-fit and connector evaluations, and validation testing.

• Develop and maintain BOMs, product documentation, and assembly instructions.

• Participate in design reviews and technical risk assessments for avionics packaging solutions.

• Support subcontractor or supplier activities related to manufacturing and integration of mechanical packaging hardware.

Basic Qualifications (Required Skills & Experience)

• Minimum 5+ years of relevant experience in mechanical packaging for avionics, aerospace, or defense electronic systems.

• Proficiency with CAD tools (SolidWorks or equivalent) for 3D modeling of PCBAs, housings, and assemblies.

• Experience with SWaP optimization techniques for avionics or mission-critical electronics.

• Strong background in PCBA mechanical integration (sizing, stacking, press-fit connectors, component clearance, and fastening methods).

• Knowledge of materials and coatings suitable for avionics housings under vibration, shock, and thermal cycling environments.

• Familiarity with DFM, DFA, and DFT best practices for aerospace or defense production.

• Experience with structural and thermal analyses using ANSYS Mechanical, Icepak, or equivalent tools.

• Skilled in mechanical tolerance analysis and GD&T per ASME Y14.5.

• Hands-on experience supporting prototype builds, lab testing, and design validation.

• Strong documentation and communication skills, including requirements definition and design reporting.

Preferred Qualifications

• Experience applying RTCA DO-160, MIL-STD-810, and MIL-STD-1540 environmental requirements to avionics packaging.

• Background in lightweight, ruggedized mechanical designs for UAV/UAS or aerospace applications.

• Knowledge of thermal management approaches for avionics packaging, including conduction cooling, thermal interface materials, and heat sinking.

• Familiarity with miniaturization techniques for high-density PCBAs and advanced interconnect strategies.

• Experience with additive manufacturing or other advanced manufacturing methods for aerospace packaging.

• Working knowledge of IPC-2221/2222 PCB design standards for mechanical-electrical integration.

• Experience with supplier engagement, cost trade studies, and manufacturability reviews for avionics hardware.

• Familiarity with Model-Based Systems Engineering (MBSE) tools such as Cameo for avionics subsystem design integration.

Salary Range: $140,000-170,000

The actual salary offered is dependent on various factors including, but not limited to, location, the candidate’s combination of job-related knowledge, qualifications, skills, education, training, and experience 

MANDATORY FOR ALL REMOTE/HYBRID AND/OR CALIFORNIA, COLORADO, MARYLAND, CONNECTICUT, ILLINOIS, MINNESOTA, VERMONT, MASSACHUSETTS, NEVADA, NEW YORK, RHODE ISLAND, WASHINGTON STATE & CINCINNATI, OHIO, JERSEY CITY, NEW JERSEY, TOLEDO, OHIO BASED ROLES. 

Note: Due to the nature of the work, only US Persons (citizens or permanent residents) need apply for this position.

ALTEN Technology is an Equal Opportunity Employer. Our Policy is to extend opportunities to qualified applicants and employees on an equal basis regardless of an individual’s age, race, color, sex, religion, national origin, disability, sexual orientation, gender identity/expression or veteran status.

Please beware of job seeker scams and see this important notice on our careers page for more information about our recruiting process.

Compliance Notice: Alten USA is a federal contractor subject to the requirements of the Vietnam Era Veterans’ Readjustment Assistance Act (VEVRAA) and Executive Order 11246. We are an Equal Opportunity Employer and consider all qualified applicants without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, disability, or veteran status.

Drug Screening Requirement: As a federal contractor, Alten USA maintains a drug-free workplace. All candidates selected for employment will be required to successfully complete a pre-employment drug screening as a condition of hire.