Senior Mechanical Design Engineer

Pulse Space Inc. develops advanced photonics and high-power laser systems for industrial, defense, and scientific applications. Our team drives innovation in kW-class fiber laser architectures, beam combining techniques, and next-generation directed-energy platforms.

We are seeking a Senior Mechanical Design Engineer to lead the design, analysis, and integration of mechanical systems for our satellite platforms and laser payloads. This role requires both creative problem-solving and rigorous engineering discipline — you will develop hardware from initial concept through qualification testing and flight production. You will collaborate with optical, electrical, thermal, and systems engineers to deliver space-qualified mechanical systems that enable our mission-critical payloads.

In this role, you will

• Design satellite structural assemblies, payload housings, and precision optomechanical mounts using CREO or equivalent 3D CAD software
• Perform structural analysis (static, dynamic, modal) and thermal analysis to ensure designs meet launch loads, on-orbit environments, and operational requirements
• Design deployable mechanisms and articulation assemblies with emphasis on reliability, mass efficiency, and performance in the space environment
• Develop thermal management architectures including conductive paths, radiators, heat pipes, and interface designs to maintain optical and electronic components within operating limits
• Apply GD&T principles to drawings and models to ensure manufacturability, inspectability, and assembly tolerance stack-up closure
• Drive design for manufacturing (DFM) and design for assembly (DFA) — optimize part count, standardize fasteners, reduce process complexity, and enable high-rate production
• Select materials, coatings, and surface treatments appropriate for space environments: outgassing requirements, thermal cycling, radiation exposure, and micrometeorite resistance
• Build and execute qualification test plans: vibration, shock, thermal vacuum, and functional performance testing to validate designs against requirements
• Work closely with optical engineers to design kinematic mounts, alignment features, and optomechanical interfaces that maintain beam quality and pointing accuracy
• Support integration and test activities, troubleshoot hardware issues, and implement design improvements based on test data and on-orbit performance

What you bring

• B.S. or higher in Mechanical Engineering, Aerospace Engineering, or closely related discipline
• 5+ years of hands‑on experience designing mechanical systems for space, defense, or high‑reliability applications
• Proficiency in 3D CAD software (CREO strongly preferred; NX, SolidWorks, or similar also considered)
• Strong understanding of mechanical engineering fundamentals: stress analysis, fatigue, fracture mechanics, heat transfer, and dynamics
• Experience with finite element analysis (FEA) tools for structural and thermal simulation (e.g., Ansys, Nastran, Abaqus, or equivalent)
• Working knowledge of geometric dimensioning and tolerancing (GD&T) per ASME Y14.5
• Familiarity with space environment constraints: vacuum, thermal cycling, radiation, launch loads, and material compatibility
• Demonstrated ability to own hardware from concept through production, including design trades, analysis, testing, and documentation
• Strong communication skills and ability to work effectively in cross‑functional teams

What will set you apart

• M.S. in Mechanical Engineering or Aerospace Engineering
• Experience designing flight hardware for space vehicles or satellite payloads that have flown or been qualified for flight
• Hands‑on experience with precision optomechanical systems: kinematic mounts, athermalization techniques, alignment methods, and stability requirements
• Background in deployable mechanisms (solar arrays, antennas, booms) or pointing/articulation systems (gimbals, scan mirrors, reaction wheels)
• Knowledge of composite materials, laminate analysis, and composite manufacturing processes
• Experience with thermal control design: heat pipes, phase‑change devices, MLI blankets, radiator sizing, and thermal interface materials
• Familiarity with additive manufacturing (DMLS, SLM) for space applications and design for additive manufacturing principles
• Track record of taking hardware from early prototypes to high‑rate production in aerospace or defense programs
• Experience with scripting or programming (Python, MATLAB) for design automation, parametric studies, or data analysis
• Active U.S. security clearance or eligibility to obtain one is a plus

What we offer

• Competitive salary and equity participation commensurate with experience
• Comprehensive benefits: health, dental, vision, and 401(k) with company match
• The chance to work on state‑of‑the‑art laser systems with tangible real‑world impact
• A collaborative, fast‑paced R&D culture that values technical excellence
• Professional development support including conference travel and continuing education