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The Opportunity:
The Project Engineer will drive successful product introduction and lifecycle management of advanced optical communications terminals for space applications. This role combines systems-level technical problem-solving with cross-functional project leadership across optical, mechanical, electrical, and thermal subsystems. You'll work on complex electro-opto-mechanical systems requiring deep technical understanding of precision manufacturing, system integration, and aerospace hardware development throughout the entire product lifecycle—from new product introduction through production ramp and rate/sustaining production and end-of-life.
This role isn't just project management—it requires a strong technical leader who understands the physics and engineering principles behind our systems. You'll need to read drawings, debug hardware failures, challenge engineering assumptions, and make technically informed decisions about manufacturing feasibility. This role will require strong technical communication skills to properly exchange information with design engineering, manufacturing support organizations, suppliers, executive leadership and customers.
Responsibilities:
- Collaborate with cross-functional teams (R&D, Design, Manufacturing, Test, Quality, Operations) to ensure Design for Manufacturability (DFM) and Design for Assembly (DFA) for multi-disciplinary system assemblies including opto-mechanical structures, electronics integration, and thermal management solutions.
- Drive manufacturing readiness for new products by leading pilot builds, process validations (IQ/OQ/PQ), customer facing operational readiness reviews (PRR, MRR, TRR), and production transfer activities in compliance with ISO 9001 and internal quality systems.
- Own end-to-end manufacturing process development, optimization, documentation, and lifecycle management. This will require collaboration with design and manufacturing engineering teams to seamlessly introduce product changes, improve existing processes, and manage product transitions. This effort will include outlining updates to process flows, work instructions, manufacturing routings, BOMs, tooling specifications, and equipment requirements.
- Lead product lifecycle phases from new product introduction (NPI) planning through production ramp, sustaining operations, continuous improvement, and end-of-life management, ensuring timely execution and adherence to schedules, budgets, and resource allocation.
- Develop and manage comprehensive project plans with schedules, milestones, risk assessments, and mitigation strategies while coordinating multiple simultaneous projects across various lifecycle stages.
- Translate high-level product and engineering requirements into actionable technical direction for manufacturing, operations, and production personnel while maintaining awareness of ongoing work to proactively identify gaps, conflicts, and integration risks.
- Perform technical troubleshooting and root cause analysis during new product ramp-up and rate production, resolving manufacturing challenges across mechanical, optical, thermal, and electrical subsystems while driving continuous improvement initiatives.
- Develop and lead operator training strategies to ensure production readiness, including technical procedures for precision assembly, contamination control, and system-level verification throughout the product lifecycle.
Qualifications:
Required:Â
- Bachelor's degree in Engineering (Mechanical, Manufacturing, Electrical, Optical, Aerospace, Systems Engineering, or related technical discipline)
- 5+ years of experience in product lifecycle engineering, manufacturing engineering, or process development managing complex projects in precision manufacturing operations (aerospace, space systems, optics, medical device, or advanced instrumentation).
- Systems engineering mindset with ability to understand technical interactions and trade-offs across multiple disciplines (mechanical, optical, electrical, thermal).
- Proficiency with engineering tools (CAD software: SolidWorks, CREO; PLM systems), data analysis tools (Excel, MATLAB, Python, or equivalent), tolerance analysis, GD&T, and ability to perform technical root cause analysis.
- Experience with precision manufacturing processes such as: CNC machining, optical assembly, electronics integration, cleanroom operations, adhesive bonding, or environmental testing (thermal cycling, vibration, TVAC).
- Proven experience supporting full product lifecycle including new product introduction (NPI), production ramp, sustaining engineering, process optimization, and continuous improvement initiatives with hands-on technical involvement.
- Well-rounded project management background with experience in DoD or Space environment, including familiarity with aerospace qualification standards and environmental testing requirements.
- Demonstrated ability to translate high-level technical direction into actionable engineering guidance and align technical priorities with available resources and ongoing work. Leverage strong interpersonal skills to engage with diverse stakeholders and work effectively in cross-functional technical teams.
- Lean / Six Sigma experience with application to manufacturing process improvement and sustaining operations.
Desired:
- MS degree in Mechanical, Electrical, Optical, Aerospace, Systems Engineering, or related technical field.
- Deep expertise in one or more areas: optical systems (alignment, bonding, testing), precision mechanical assemblies, electronics integration, thermal management, or control systems.
- Knowledge of space qualification standards (NASA, MIL-STD, ECSS) and experience manufacturing space-grade hardware.
- Experience with satellite systems, optical/laser communications, aerospace instrumentation, or multi-disciplinary space payloads.
- Familiarity with engineering analysis tools: FEA (ANSYS, Abaqus), thermal simulation, optical modeling (Zemax, Code V), or electrical simulation.
- PMP Certification
- Lean Greenbelt or Six Sigma certification
What You Can Expect:
 A culture of integrity.
At CACI, we place character and innovation at the center of everything we do. As a valued team member, you’ll be part of a high-performing group dedicated to our customer’s missions and driven by a higher purpose – to ensure the safety of our nation.
An environment of trust.
CACI values the unique contributions that every employee brings to our company and our customers - every day. You’ll have the autonomy to take the time you need through a unique flexible time off benefit and have access to robust learning resources to make your ambitions a reality.
A focus on continuous growth.
Together, we will advance our nation's most critical missions, build on our lengthy track record of business success, and find opportunities to break new ground — in your career and in our legacy.
Pay Range:
There are a host of factors that can influence final salary including, but not limited to, geographic location, Federal Government contract labor categories and contract wage rates, relevant prior work experience, specific skills and competencies, education, and certifications. Our employees value the flexibility at CACI that allows them to balance quality work and their personal lives. We offer competitive compensation, benefits and learning and development opportunities. Our broad and competitive mix of benefits options is designed to support and protect employees and their families. At CACI, you will receive comprehensive benefits such as; healthcare, wellness, financial, retirement, family support, continuing education, and time off benefits.
The proposed salary range for this position is:
$71,500 - $150,200Learn more about this Employer on their Career Site
