By Light Professional IT Services LLC readies warfighters and federal agencies with technology and systems engineered to connect, protect, and prepare individuals and teams for whatever comes next. Headquartered in McLean, VA, By Light supports defense, civilian, and commercial IT customers worldwide.

We are seeking a Senior or Principal Mechanical Engineer to lead mechanical design across a diverse set of flight simulation and training devices. While this role will primarily support Deployable Mission Rehearsal Trainer (DMRT) development, it will also provide mechanical engineering leadership for traditional flight simulator programs.

This position is ideal for a seasoned engineer who enjoys working across multiple programs, balancing innovation with execution, and translating training system requirements into robust, high-fidelity mechanical solutions. The role emphasizes mechanical architecture, mounting and interface design, and system integration across complex training systems.

• Serve as the mechanical engineering lead during Systems Engineering Technical Reviews (SETR), presenting designs, supporting technical decisions, and driving closure of mechanical action items through SRR, PDR, and CDR
• Lead mechanical architecture and design for flight simulation and training systems, including structures, equipment mounting, control interfaces, and sustainment-focused design standards.
• Define and manage mechanical interfaces, alignment requirements, and integration constraints across DMRT and traditional simulator platforms (containerized and facility-based).
• Design and integrate cockpit hardware, flight controls, visual systems, and MR (Mixed Reality) headsets, including mounts, sensors, and cable routing.
• Collaborate with systems, software, electrical, manufacturing, and program teams to support integration, design reviews, and subsystem acceptance.
• Develop detailed 3D CAD models, assemblies, drawings, and fabrication-ready documentation using Autodesk Inventor and AutoCAD.
• Support rapid prototyping and development using in-house 3D printing.
• Execute mechanical verification and validation activities, including fit, form, function, and failure mode assessments.
• Mentor junior engineers and serve as a mechanical subject matter expert, promoting best practices in design, configuration management, and manufacturability.

• BS in Mechanical Engineering or related discipline
• 10+ years of mechanical engineering experience with increasing technical leadership.
• Experience supporting flight simulators or complex electromechanical systems.
• Expert proficiency in Autodesk Inventor (SolidWorks experience considered with rapid transition to Inventor).
• Strong foundation in structural design, tolerancing, composites, sheet metal, and precision fabrication.
• Proven experience integrating functional 3D-printed components into production-level systems.
• Proven configuration management and control of mechanical CAD data and drawings.
• Ability to support multiple programs across the full development lifecycle.

• Experience integrating complex simulator subsystems and managing mechanical interfaces across teams or suppliers.
• Background in defense or aerospace training systems.
• Hands-on experience integrating computer and electronic hardware into high-reliability systems.
• Strong customer-facing communication skills, written and verbal.
• Familiarity with MIL-STD, ergonomic, safety, and SWaP-driven design requirements.

• Ability to obtain and maintain a Secret Clearance