Staff Mechanical Engineer, Hardware Test (R4325)

What you'll do:

• Own the end-to-end mechanical test strategy for flight hardware, including requirements definition, architecture, design, build, and lifecycle sustainment of test systems.
• Lead the design and development of fixed and field-deployable test stands, fixtures, and ground support equipment interfacing with aircraft structures, propulsion systems, motors, avionics, and subsystems.
• Drive structural, thermal, and fatigue analysis to validate designs for harsh military environments, transportability, and repeated use.
• Serve as the technical decision-maker for mechanical test systems, balancing performance, cost, schedule, manufacturability, and maintainability.
• Review and approve detailed CAD models, drawings, and specifications; set standards for design quality, documentation, and configuration control.
• Lead and participate in cross-functional design reviews (PDR/CDR/TRR), advocating for testability, simplicity, and rapid learning.
• Partner with suppliers and manufacturing teams to ensure scalable, cost-effective production and long-term sustainment of test hardware.
• Mentor and guide junior and mid-level engineers, setting technical direction and raising the overall quality bar of the team.
• Support flight test and field operations, including rapid troubleshooting, test system modification, and on-site integration when required.

Required qualifications:

• B.S. in Mechanical Engineering or related STEM field.
• 7+ years of experience designing mechanical systems for aerospace, ground support equipment, test infrastructure, or heavy industrial systems.
• Deep mastery of mechanical fundamentals, including structural mechanics, materials, dynamics, and thermal behavior.
• Expert-level proficiency in CAD tools (NX, CATIA, SolidWorks, or equivalent), including complex assemblies and released drawings.
• Strong experience with structural analysis, material selection, and manufacturing processes for ruggedized, high-reliability systems.
• Hands-on experience designing test stands, fixtures, or support equipment for aerospace or similarly demanding applications.
• Proficiency with FEA, thermal analysis, and fatigue/lifecycle testing.
• Proven ability to operate in a fast-paced, ambiguous environment, owning problems from concept through execution.
• Demonstrated history of high ownership, strong judgment, and collaborative leadership.

Preferred qualifications:

• Experience supporting UAS, aircraft, propulsion, or large aerospace-grade structures.
• Experience designing field-deployable or expeditionary test systems.
• Ability to rapidly prototype and manufacture designs in a machine shop or lab environment.
• Experience owning large-scale test or facilities projects from concept through deployment.
• Knowledge of hydraulics, NDE/NDT methods, and aerospace structural validation practices.
• Prior experience acting as a technical lead or subject-matter expert for test or ground systems.