Mechanical Engineer, Staff at Allen Control Systems (Austin, TX)Mechanical Engineer, Staff

Company Overview ACS (Allen Control Systems) is a defense technology company building precision robotic systems for the United States and its allies. Founded by two former U.S. Navy electrical engineers with deep experience in robotics and software, ACS brings together AI, computer vision, precision motion, and advanced hardware to solve complex defense challenges across land, air, and maritime environments.

Our flagship product, Bullfrog, is an autonomous precision weapon system that transforms existing weapons into highly accurate counter-drone systems — giving warfighters a scalable, cost-effective response to one of the fastest-growing threats on the modern battlefield. Bullfrog is deployed with U.S. forces, and ACS works with organizations throughout the U.S. military and national security community.

Following a $200 million Series B at a $2.2 billion valuation, ACS is rapidly expanding manufacturing, accelerating Bullfrog deployments, and developing the next generation of autonomous battlefield systems. This is an opportunity to join a proven, fast-moving team and help scale technology with direct, real-world impact on national security.

ACS is headquartered in Austin, Texas, with additional operations in Alexandria, Virginia; Mountain View, California; and Huntsville, Alabama. For more information, visit allencontrolsystems.com allencontrolsystems.com.

Position Overview:

We are looking for a highly experienced Mechanical Designer with strong expertise in mechanical simulations and electromechanical integration. The ideal candidate will be well-versed in designing for durability, reliability, and robustness according to MIL-STD-810 standards. You will play a critical role in ensuring our products meet stringent environmental, vibration, and shock requirements, while also integrating complex electromechanical components into our systems.

What You'll Do:

• Design and develop mechanical systems that meet MIL-STD-810 specifications, ensuring robustness under vibration, shock, thermal, and environmental conditions.
• Perform mechanical simulations (FEA, modal, vibration, thermal) to assess the durability and reliability of designs under operational stress.
• Collaborate with electrical and systems engineers to integrate electromechanical components, ensuring seamless interaction between mechanical structures and electrical systems.
• Lead structural integrity testing and analysis, ensuring designs meet environmental test criteria for military-grade systems.
• Develop and document mechanical design specifications, including detailed drawings, simulation reports, and testing protocols.
• Conduct testing and validation to ensure that mechanical designs meet the required performance and safety standards.
• Support prototype development and work closely with manufacturing teams to ensure designs are feasible and cost-effective.
• Maintain a strong focus on product quality, safety, and reliability, adhering to Design for Manufacturing and Design for Reliability best practices.
• Contribute to cross-functional design reviews, identifying potential mechanical and electromechanical risks early in the development cycle.

What You'll Need:

• A passion for designing robust mechanical systems that can operate in harsh environments.
• Previous robotics, robotics lab, medical robotics, or autonomy experience is required.
• 9+ years of experience in mechanical design, including expertise in electromechanical integration.
• Bachelor's or Master's degree in Mechanical Engineering or a related field.
• R&D experience
• Hands-on experience performing structural, vibration, and thermal simulations using tools such as ANSYS, SolidWorks (preferred).
• Proficient in 3D CAD software such as SolidWorks (preferred), CATIA, or Creo.
• Strong understanding of MIL-STD-810 requirements for mechanical durability, including vibration, shock, temperature, and humidity testing.
• Skilled in electromechanical integration, ensuring compatibility between mechanical structures and electrical components (e.g., wiring harnesses, sensors, actuators).
• Experience conducting Finite Element Analysis (FEA), Modal Analysis, and Thermal Analysis.
• Collaborate effectively with electrical, software, and systems engineers to develop integrated solutions.
• Familiar with Design for Manufacturing (DFM) and Design for Reliability (DFR) principles.

You'll Stand Out:

• Direct experience working with MIL-STD-810 (e.g., vibration, temperature, and shock tests).
• Knowledge of MIL-S-901D for naval shock testing and MIL-STD-461 for EMI/EMC standards.
• Familiarity with Electromagnetic Compatibility (EMC) considerations in mechanical design.
• Experience in rapid prototyping and Additive Manufacturing (3D Printing).
• Familiarity with fluid dynamics and heat transfer principles.
• Experience with shock absorption and damping systems for mechanical structures.

What We Offer:

• Competitive salary
• ACS Equity Package
• Health, Dental, Vision Insurance
• Paid Time Off

Allen Control Systems is an Equal Opportunity Employer, providing equal employment opportunities to all employees and applicants for employment. Allen Control Systems prohibits discrimination and harassment of any type without regard to race, color, religion, age, sex, national origin, disability status, genetics, protected veteran status, sexual orientation, gender identity or expression, or any other characteristic protected by federal, state or local laws.