LufCo · 4 hours ago
Electro-Mechanical Survivability Engineer (Systems Design & Hardening)
Aberdeen, MD
Full-time
Onsite
Senior Level
$130K/yr - $180K/yr
7+ years expLufCo is seeking a Senior Electro-Mechanical Survivability Engineer to serve as the lead architect for the electrical and mechanical integrity and environmental hardening of integrated hardware. This role involves designing ruggedized enclosures and ensuring that sensitive components survive extreme operational conditions.
AnalyticsAppsIT ManagementSoftwareSoftware Engineering
No H1B
Security Clearance RequiredU.S. Citizen Only
Responsibilities
Bespoke Structural Design: Lead the ground-up mechanical design of ruggedized enclosures and internal sub-frames. Responsible for the primary load paths and structural survival of the entire integrated system
Integrated System Hardening: Identify and mitigate mechanical vulnerabilities in high-density computing and communication hardware, such as reinforcing un-ruggedized cards, securing high-speed cabling, and hardening RF connectors against shear forces
COTS/NDI Integration: Design bespoke internal 'exo-skeletons' and isolation strategies that allow commercial servers, switches, and radios to operate far beyond their original structural specifications
Shock & Vibration Isolation Architecture: Design and integrate complex isolation systems—including wire-rope, elastomeric, or 3D-printed energy-absorbing lattices—specifically tuned to protect delicate internal electronics from tactical vehicle vibration and high-impact events
Additive Manufacturing for Hardening: Leverage Design for Additive Manufacturing (DfAM) to create hyper-optimized, lightweight structures. Use AM for part consolidation, weight reduction, and the creation of 'conformal' structural supports that wrap around uniquely shaped COTS components
Environmental Sealing & Ingress Protection: Design and validate IP67/68-rated seals. Ensure the chassis architecture accounts for pressure equalization during rapid altitude changes while preventing the ingress of sand, dust, and salt fog
Structural FEA & Dynamic Simulation: Perform high-fidelity Finite Element Analysis (FEA), including linear/non-linear dynamics and fatigue analysis, to simulate environmental and operational stress profiles
Verification & Standards Compliance: Direct all structural validation and correlation efforts to ensure both bespoke designs and integrated hardware meet or exceed MIL-STD-810H and MIL-S-901D requirements
RF Shielding & EMI/EMC: Expertise in MIL-STD-461 (Electromagnetic Interference). This involves designing Faraday cages, selecting conductive gaskets, and ensuring that high-speed processors don't jam the radio receivers sitting right next to them
SWaP-C Optimization: In expeditionary gear, 'Size, Weight, Power, and Cost' are the primary constraints, and frequently at odds with survivability goals
Qualification
Required
BS in Electrical, Electronics, or Mechanical Engineering, Structural Engineering, or a related field
7+ years of experience in electro-mechanical design and systems integration, specifically within the Defense, Aerospace, or Ruggedized Industrial sectors
Expert proficiency in FEA dynamics tools (e.g., Ansys Mechanical, Abaqus, LS-DYNA, or Simcenter 3D)
Proven track record of designing complex mechanical assemblies and 'hardening' commercial electronics for high-reliability military use
Experience with generative design and lattice-optimization tools (e.g., nTopology or Altair Inspire) to integrate damping directly into structural components
Deep knowledge of fatigue limits, the anisotropic properties of AM-produced alloys, and galvanic compatibility in expeditionary environments
Expertise in interpreting Power Spectral Density (PSD) and shock response spectra (SRS) to validate system survival
Mastery of MIL-STD-810H (Vibration/Shock/Drop), MIL-S-901D, and MIL-STD-1472
Expertise in circular connectors (the 'Gold Standard' for military comms) and high-speed fiber optic interconnects
Understanding how to protect sensitive computing gear from 'dirty' power coming from military vehicles or field generators (surges, spikes, and ripples)
Ability to travel as required
Standard office environment with occasional requirements to visit client sites, labs, or field environments
TS/SCI clearance (able to process, US citizenship is a must)
Preferred
MS is preferred
Benefits
Paid Time Off
401K Contribution and Employer Match Contributions
Medical, Dental, and Vision Coverage
Company
LufCo
LufCo provides software engineering and analytic resources for commercial sectors.
51-200 employees
Funding
Current Stage
Growth StageLeadership Team
Heather Lufburrow
President & CEO
Company data provided by crunchbase