Staff Mechanical Engineer

Job Details

The Staff Mechanical Engineer is a key contributor to the development of advanced electro-mechanical and opto-mechanical subsystems for telescopes, beam directors, and related equipment. In this role, you will be responsible for designing and analyzing components and assemblies, including precision mechanisms, sensors, and optical support structures that operate in challenging environments ranging from terrestrial to spaceborne. You will generate conceptual designs and CAD models, perform preliminary structural and thermal analyses, and oversee the drafting and release of engineering drawings. Additionally, you will support system integration and testing by developing tooling and contributing to test plans and procedures.

Responsibilities

• Design and develop complex mechanical systems: Collaborate on the design and development of large-scale mechanical systems and precision mechanisms, optical support assemblies, and drive systems for demanding applications.
• Contribute to the development of drives, positioning mechanisms, and optical metering structures to ensure performance and stability over the operational lifecycle and in challenging environments.
• Perform preliminary structural and thermal analyses: Conduct initial structural and thermal assessments, such as finite element analyses (FEA) for gravity sag, thermal distortion, and dynamic response, to guide design decisions and ensure feasibility.
• Create and manage detailed engineering designs: Develop and maintain CAD models of mechanical components and subassemblies, generate detailed part and assembly drawings, and perform tolerance analysis and budgeting to ensure manufacturability, precision, and compliance with performance specifications.
• Support assembly, integration, and testing: Assist in system-level integration and testing by designing and fabricating tooling, reviewing work instructions, and developing test plans to validate system functionality and achieve project objectives.
• Interface with vendors to answer questions and ensure the successful fabrication, inspection, and delivery of high-quality components.
• Participate in the characterization of optical supports and mechanical systems to ensure compliance with design, environmental, and performance requirements.

Qualifications

• Minimum two years of related experience in a professional role with a Bachelor’s degree or related discipline.
• Minimum of one year of experience with a Master’s degree.
• Experience in optomechanical or precision mechanism design: Familiarity with optomechanical design principles and/or precision mechanism development.
• Knowledge of optical system design: Experience working with optical systems from concept to production, including optics, mounting strategies, Geometric Dimensioning and Tolerancing (GD&T), manufacturability, and cost estimation.
• Competence with 3D CAD software: Proficiency with 3D CAD tools; experience using SOLIDWORKS and Solidworks PDM is preferred.
• Familiarity with analysis methods and tools: Understanding of thermal, vibrational, and shock analysis methods for optical systems or precision mechanisms. Experience with analysis tools such as Femap/NX Nastran, Simcenter 3D, Mathcad, Matlab, and/or Star CCM+ is preferred. Familiarity with Sigmadyne’s SigFit software is a plus.
• Experience with precision mechanisms: Hands-on experience in the design, analysis, assembly, and testing of precision mechanisms, including motor and bearing sizing, encoder selection, lubrication, and flexure design.
• Understanding of advanced materials: Familiarity with designing subsystems that use specialized materials such as ceramics, specialty metals (e.g., Invar), carbon fiber composites, and optical coatings.
• Competence with systems engineering tools and practices: Knowledge of methodologies such as error budgeting, Failure Modes and Effects Analysis (FMEA), and Technical Performance Measure (TPM) tracking.
• Exposure to optical systems integration and testing: Experience with integrating, aligning, or testing optical systems is highly valued, and familiarity with optical and dynamic testing or data analysis is a plus.
• Design for assembly and integration: Understanding of key principles for designing complex optomechanical systems, including alignment planning, tolerance stack analysis, and assembly workflows.
• Strong interpersonal and organizational skills: Effective communication and collaboration skills with a proven ability to work independently or as part of a multidisciplinary team. Attention to detail and a structured approach to problem-solving are essential.