Design Engineer

SAIC is seeking an organized and motivated Design & Producibility Engineer who will work effectively in a fast-paced environment, specifically with submarine launched weapons / UUV systems and related test equipment. Candidates will be responsible to work in a team environment with government and SAIC engineers to design, development, test and implement modern systems for the U.S. Navy.

This position offers a remote work arrangement, combining remote work with in-office collaboration while on work travel. We emphasize flexibility and productivity while maintaining a strong sense of teamwork and communication. Our team works both remotely and from our offices in Middletown RI, Charleston SC, and Silverdale WA, ensuring a balance of independent work and in-person collaboration.

General Description of Role/Responsibilities:

1. Mechanical Design, CAD Models, and Drawings Create, convert, and maintain production-ready 3D CAD models and 2D drawings for assemblies and sub-assemblies, including legacy 2D-to-model conversions. Embed complete product definition into models/drawings: GD&T per ASME Y14.5, material specifications, surface finish and coating/plating requirements, part numbers, revision history, and critical notes (MBD/TDP-quality data sets). Perform tolerance stack-up analyses and dimensional studies to ensure fit, function, and interchangeability across mating interfaces. Support drawing tree development, drawing release, and incorporation of redlines/ECPs through the configuration management process. Maintain configuration-controlled material property libraries and design data in PDM/PLM tools (e.g., Windchill).

2. Producibility and Design for Manufacturing Create, convert, and maintain production-ready 3D CAD models and 2D drawings for assemblies and sub-assemblies, including legacy 2D-to-model conversions. Develop producibility models and perform DFM analyses to optimize part geometry, reduce manufacturing risk, and improve yield. Perform quantitative quality assurance calculations supporting inspection planning and process capability assessment. Support supplier tooling evaluations, manufacturing process validation, and first article inspection planning. Support development of the formal manufacturing qualification process, ensuring processes, assembly lines, and suppliers meet readiness criteria.

3. Hazard, Failure, and Reliability Analysis Perform Failure Modes and Effects Analysis (FMEA) and Failure Modes, Effects, and Criticality Analysis (FMECA) at the component and assembly level per MIL-STD-1629 methodology or program-directed process. Construct and maintain Fault Tree Analyses (FTA) for critical system-level failure conditions; identify cut sets, single-point failures, and candidate design mitigations. Support system safety hazard analyses per MIL-STD-882 (PHA, SSHA, O&SHA as assigned), including hazard identification, risk assessment (severity/probability), and mitigation tracking to closure. Feed failure analysis and hazard analysis results back into design decisions, test planning, and inspection criteria. Support reliability modeling and reliability assessment activities; use field data, test data, and stress-test feedback to drive design refinement.

4. Test, Verification, and Quality Draft and finalize Assembly Confidence Test (ACT) plans and inspection plans for assigned assemblies. Support development of master test strategy, detailed test plans, test function lists, and test equipment requirements. Execute and support confidence testing, EDM kit verification, and test report preparation. Map requirements to verification methods (analysis, inspection, demonstration, test) and support closure of verification matrices.

5. Requirements and Systems Engineering Support Support capture, allocation, and management of system-level requirements with full traceability from stakeholder needs to sub-assembly level (SSS-2 to SSS-3), using DOORS Next Gen. Support development of the Functional Item Replacement (FIR) tree and functionally allocated baseline documentation. Support identification of hanging-parent and orphan requirements and documentation of allocation rationale.

• Bachelor’s degree and two years of experience; years of experience accepted in lieu of degree.
• 2+ years of hands-on experience in mechanical design, drafting/CAD, manufacturing, quality, or hardware test in lieu of a bachelor’s degree (per company degree-substitution policy).
• Demonstrated proficiency creating production-quality 3D CAD models and 2D drawings (SolidWorks or equivalent), including model-based definition.
• Working knowledge of GD&T per ASME Y14.5 and tolerance stack-up analysis.
• Experience with manufacturing processes (machining, casting, coatings/plating, assembly) and design-for-manufacturing principles.
• Experience developing or executing test plans, inspection plans, or quality acceptance criteria for hardware.
• Ability to read, interpret, and flow down engineering specifications and drawings.
• Strong written communication: able to author engineering documents, analysis worksheets, and test reports suitable for customer delivery.
• U.S. citizenship and eligibility for a security clearance; ability to work with ITAR-controlled data.
• Experience on DoD/Navy hardware programs; familiarity with TDPs, CDRLs, and SETR-style design reviews (PDR/CDR).
• Exposure to FMEA/FMECA, fault tree analysis, root cause analysis (e.g., 8D, fishbone), or system safety processes (MIL-STD-882).
• Exposure to FEA tools and structural/thermal analysis concepts.
• Familiarity with PDM/PLM systems (Windchill) and requirements tools (DOORS Next Gen).
• Experience supporting configuration audits (PCA/FCA), first article inspections, or supplier source inspections.
• Professional certificates (e.g., GD&T certification, CSWP, ASQ CQE/CRE), or documented equivalent training.