Sr. Mechanical Engineer

TRL11 is seeking a hands-on Senior Mechanical Engineer to own the mechanical development of space avionics and electro-optical imaging systems from initial requirements through production and product sustainment.

This role will have broad responsibility across the full product lifecycle, including requirements definition and verification, mechanical architecture, detailed design, drawing release, supplier selection, manufacturing engineering, environmental testing, and ongoing product support. The Senior Mechanical Engineer will work closely with cross-functional teams and customers to deliver reliable hardware for demanding space environments.

The ideal candidate is a strong individual contributor who is comfortable making technical decisions, working directly with vendors, technicians, and customers, and remaining accountable for a product after the initial design is released.

Key Responsibilities

• Own the mechanical development and sustainment of space avionics and electro-optical products.
• Translate system, optical, thermal, structural, environmental, and manufacturing needs into mechanical requirements.
• Develop mechanical architectures, concepts, detailed designs, drawings, and release packages.
• Design enclosures, optical assemblies, structural components, thermal interfaces, and precision electromechanical assemblies.
• Perform tolerance analysis, material selection, fastener selection, interface definition, and design-for-manufacturing reviews.
• Support prototype builds, first-article inspection, assembly development, troubleshooting, and design iteration.
• Identify and source initial components and manufacturing partners.
• Evaluate and qualify machine shops, fabrication vendors, coating suppliers, and other external manufacturers.
• Develop manufacturing processes, assembly instructions, tooling, inspection requirements, and acceptance criteria.
• Plan and execute system verification testing, including imaging performance and environmental testing.
• Investigate production and field issues, lead root-cause analysis, and implement corrective actions.
• Maintain released designs through configuration changes, obsolescence, cost reduction, and reliability improvements.
• Provide technical mentorship and support the continued development of TRL11’s mechanical engineering practices.

Requirements

• Basic
• Bachelor’s degree in mechanical engineering, aerospace engineering, or a related field.
• At least 5 years of relevant mechanical product-development experience.
• Experience owning complex hardware through design, release, manufacturing, test, and sustainment.
• Strong proficiency in 3D CAD, engineering drawings, GD&T, tolerance analysis, and configuration-controlled design release with tools such as Onshape, Solidworks, or similar.
• Experience designing precision mechanical or electromechanical assemblies.
• Working knowledge of thermal management, structural design, materials, coatings, fasteners, and manufacturing processes.
• Experience supporting environmental testing and resolving test failures.
• Experience working directly with machine shops, contract manufacturers, and component suppliers.
• Ability to balance performance, schedule, cost, reliability, and manufacturability.
• Strong technical judgment, attention to detail, and written and verbal communication skills.
• Willingness to work hands-on with prototypes, flight hardware, test equipment, and production personnel.
• Preferred
• Experience with spacecraft, space avionics, cameras, telescopes, optical payloads, or other high-reliability aerospace hardware.
• Proficiency with finite element analysis, particularly thermal analysis.
• Experience with structural and thermo-mechanical simulation.
• Experience with optical-mechanical analysis, optical alignment, line-of-sight stability, or STOP analysis.
• Familiarity with thermal-vacuum, random vibration, sine vibration, mechanical shock, and launch-environment qualification.
• Experience with precision machining, sheet metal, additive manufacturing, castings, adhesives, and optical mounting methods.
• Familiarity with aerospace configuration management, qualification, acceptance testing, and product-assurance practices.
• Experience transitioning products from prototype or low-rate production into repeatable manufacturing.