Senior Mechanical Engineer, Hardware Test
Senior Mechanical Engineer designing and building test fixtures, stands, and infrastructure to validate aerospace hardware including avionics, propulsion, and payloads for the X-BAT autonomous aircraft program. Requires 5+ years mechanical/test equipment experience, CAD proficiency, and hands-on prototyping skills.
About the job
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.
Skills
Mechanical Design, GD&T, Tolerance Analysis, Finite Element Analysis, FEA, Ansys, Abaqus, Nastran, Test Fixtures, Test Stands, Environmental Testing, Vibration Testing, Thermal Testing, Mil-Std-810, Do-160
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