Senior Staff Engineer, Mechanical Test (R4413)

What you'll do:

• Develop and execute test plans to validate mechanical performance, structural integrity, and environmental durability from start to finish.
• Design, build, and operate test fixtures and systems involving hydraulic actuation, mechanical linkages, and sensor instrumentation.
• Integrate and calibrate a range of sensors (e.g., load cells, pressure transducers, strain gauges, accelerometers) into test setups for accurate data collection.
• Create and maintain python scripts to provide automation, signal processing, and result visualization.
• Analyze test data, troubleshoot system behaviors, and generate detailed technical reports with design feedback.
• Collaborate with cross-functional teams including mechanical design, systems, and electrical engineering to define test requirements, run test campaigns and deliver high quality results.
• Lead CAD design of custom test equipment, prototypes, fixtures, and components, ensuring manufacturability and safety.
• Perform Finite Element Analysis to simulate mechanical performance, validate design assumptions, and correlate analytical results with test data.
• Work with metallic/composite materials in the design, fabrication, and testing of mechanical components, with consideration for their unique properties such as anisotropy, delamination risk, and layup configuration.
• Support lab safety protocols, equipment maintenance, and continuous improvement of test capabilities.

Required qualifications:

• Bachelor’s or Master’s degree in Mechanical Engineering or related field.
• 12+ years of experience in mechanical testing or product development environments.
• Strong working knowledge of hydraulic systems and their control/measurement.
• Experience with sensor selection, integration, and calibration in test environments.
• Proficiency in Python for scripting, test automation, and data analysis.
• Advanced CAD skills in Siemens NX with experience designing test hardware and prototypes.
• Excellent problem-solving skills and the ability to work independently and in team settings.
• Ability to obtain a S//SAR level security clearance desired.

Preferred qualifications:

• Hands-on experience performing MIL-STD testing (e.g., MIL-STD-810, MIL-STD-461) including vibration, shock, thermal, and EMI/EMC testing.
• Subject Matter Expert in aerospace structures and dynamics test environments.