Senior Mechanical Engineer

Job Locations


Why work at IAI/BlueHalo


At Intelligent Automation (now a BlueHalo company) our employees describe their work as reminiscent to a graduate school lab with the unique opportunity to see your innovation go beyond the research environment. At IAI/BlueHalo your work will transition to the real world, where it can make a difference.


Being on the BlueHalo team means working alongside the brightest minds in technology on the toughest challenges facing our nation – not just every once in a while, but every single day.


Together, we are leading the transformation of modern warfare and each BlueHalo employee plays a key role. That’s why our investment in you goes beyond a rewarding salary and benefits package. We’re committed to providing our people with the best opportunities to develop their skills, share their knowledge, and push their innovative ideas to the cutting-edge. Having fun doing it with a team that feels like family all across BlueHalo Nation is the ultimate perk. From Space and Directed Energy to Cyber and Intelligence to C4ISR and Air & Missile Defense, there is no limit to where you can take your career with us.


Are you ready to launch a career at BlueHalo?


Benefits, Retirement & more


Our careers benefits include but are not limited to the following:


  • Flexible/hybrid work schedule (built-in work from home days)
  • Professional development & educational assistance
  • Retirement savings with employer matching
  • Healthcare Flexible Spending Account (FSA)
  • Medical and life insurance
  • Active social committee
  • Fitness center
  • Annual profit sharing
  • Relocation expenses
  • Paid vacation & holidays


About Us


Intelligent Automation, a BlueHalo company, is a technology innovation company with an office located in Rockville, MD. It conducts state-of-the-art research and product development in the areas of Intelligent Transportation Systems, Robotics, Signal Processing, Controls, Sensor Technologies, Distributed Intelligent Systems, and more.


We specialize in providing advanced technology solutions and R&D services to federal and state agencies, and corporations throughout the United States and internationally. Our transportation portfolio includes Surface Transportation, Big Data Analytics, Controls, Signal Processing, Modeling & Simulation, and Robotics & Sensor Systems.


Intelligent Automation (a BlueHalo Company) is looking for a Senior (Level III) mechanical engineer to design and develop hardware supporting IAI/BHL research and development in the areas of robotics, inspection technology, perimeter security, electro-optics, sensing and computer vision, and advanced RF hardware.


Job Duties

  • Designing electro-mechanical systems from concept to prototype including electronics packaging, mechanism design, actuation, layout and cabling, and other elements of mechanical design
  • Developing drawings and technical data packages to support fabrication and build of mechanical parts and assemblies
  • Supporting the prototyping process, including developing bills-of-materials, managing procurement of parts, and either hands-on build or supervise technicians to build prototypes
  • Writing technical report sections and presentations for clients
  • Supporting the technical proposal process


U.S. Citizenship or Legal Permanent Resident status is required.


Required Skills

  • B.S. degree in Mechanical Engineering or equivalent discipline
  • 7+ years of relevant experience in mechanical design developing hardware in fields such as robotics, electro-optics, aerospace, or military hardware development
  • Proficiency in standard CAD modeling software such as SolidWorks and SolidWorks PDM, Autodesk Inventor, or Creo
  • Experience in creating engineering fabrication and assembly drawing packages, applying relevant standards (ASME Y14.5)
  • Strong written and verbal communication skills
  • Ability to work in a multidisciplinary team
  • Experience managing build and assembly of hardware components
  • Functional knowledge of manufacturing processes such as machining, sheet metal, rapid prototyping, and injection molding


Desired Skills

  • M.S. degree in Mechanical Engineering or equivalent discipline
  • SECRET level security clearance (preferred) or the ability to obtain clearance
  • Proficiency in SolidWorks and SolidWorks PDM
  • Proficiency in ANSYS Workbench or similar structural analysis package and experience with structural, shock, or vibration analysis
  • Proficiency in ANSYS Icepack or similar thermal analysis package for electronics cooling and packaging
  • Experience with design for shock and vibration
  • Experience with thermal management of electronics
  • Experience with developing hardware to ruggedization standards such as MIL-STD-810
  • Experience with electronics packaging considerations such as grounding, bonding, and shielding
  • Experience with designing compact electronics, such as mobile devices or wearables
  • Hands-on experience with prototyping tools (hand tools, power/bench tools)


Leading the Transformation - The BlueHalo Effect
It speaks to who we are as a company, a global protective ring that shields everything we most want to safeguard, an unbroken line that ensures our customers retain the advantage in any battlespace, from high above the Earth to deep in cyberspace. It’s who we are, a halo, a protector, the light of inspired engineering keeping our Nation safe.
Our vision is a world where national security is certain because technical superiority is assured.
Join us and become a vital element of The BlueHalo Effect!


EEO Statement 
BlueHalo is committed to hiring and retaining a diverse workforce. We are proud to be an Equal Opportunity/Affirmative Action Employer, making decisions without regard to race, color, religion, creed, sex, sexual orientation, gender identity, marital status, national origin, age, veteran status, disability, or any other protected class. U.S. Citizenship is required for most positions.
If you are an individual with a disability and would like to request a reasonable workplace accommodation for any part of the employment process, please send an email to Please indicate the specifics of the assistance needed. This option is reserved only for individuals who are requesting a reasonable workplace accommodation. It is not intended for other purposes or inquiries.


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