Senior Mechanical Engineer, Hardware Test

What you'll do

• Design and develop mechanical test fixtures, test stands, environmental test hardware, and integration tooling to support verification and validation activities.
• Create detailed CAD models, engineering drawings, assembly instructions, and manufacturing documentation.
• Support qualification, reliability, environmental, vibration, thermal, and endurance testing of X-BAT hardware.
• Design systems that interface with aircraft structures, avionics, batteries, propulsion systems, payloads, and electromechanical assemblies.
• Perform engineering analyses, including structural, thermal, and fatigue assessments, to ensure safe and reliable operation of test equipment.
• Collaborate with cross-functional teams to define test requirements and develop effective test solutions.
• Support root-cause investigations and failure analysis efforts by developing troubleshooting fixtures and diagnostic hardware.
• Work with machine shops, vendors, and manufacturing partners to fabricate and assemble test equipment.
• Assist with laboratory setup, equipment integration, and maintenance of test infrastructure.
• Contribute to design reviews and advocate for design improvements that simplify testing and increase hardware reliability.
• Support continuous improvement efforts focused on safety, test efficiency, repeatability, and scalability.

Required qualifications

• B.S. in Mechanical Engineering or related engineering discipline.
• 5+ years of experience designing mechanical systems, test equipment, aerospace hardware, or electromechanical systems.
• Proficiency with CAD software such as NX, SolidWorks, CATIA, Creo, or similar.
• Experience creating engineering drawings and releasing designs for fabrication and assembly.
• Strong understanding of mechanical design fundamentals, materials, manufacturing processes, GD&T, and tolerance analysis.
• Experience designing fixtures, tooling, test stands, or ground support equipment.
• Hands-on experience building, integrating, and troubleshooting mechanical or electromechanical systems.
• Strong analytical and problem-solving skills with the ability to work independently on moderately complex projects.
• Ability to thrive in a fast-paced development environment with evolving priorities.

Preferred qualifications

• Experience supporting aerospace, defense, robotics, automotive, or autonomous systems programs.
• Experience with finite element analysis (FEA) tools such as ANSYS, Abaqus, or Nastran.
• Familiarity with environmental, vibration, thermal, and durability testing methods.
• Experience working with instrumentation, sensors, data acquisition systems, and laboratory equipment.
• Familiarity with aerospace qualification standards such as MIL-STD-810, DO-160, or equivalent.
• Experience designing field-deployable or ruggedized test equipment.