Associate Test Systems Mechanical Design Engineer

Boeing•El Segundo, CA

5d•Onsite

About The Position

Associate Test Systems Mechanical Design Engineer Company: The Boeing Company Boeing Space, Intelligence & Weapons Systems is currently hiring multiple Associate Test Systems Design and Analysis Engineers (STE) to join us as part of our Special Test Equipment for Space Electronics team located in El Segundo, CA. The Special Test Equipment (STE) team at The Boeing Company's Satellite Development Center in El Segundo, California is seeking all levels of Electrical Engineers with skills and familiarity in Power/Digital and RF/Mixed Signal Systems for Space Applications. Our team is a critical part of Boeing's mission, ensuring the reliability and performance of advanced space electronics through the design, development, and validation of state-of-the-art testing equipment. Our engineers work on a variety of space-grade electronics, from power and digital subsystems to RF/mixed signal systems. The STE team is responsible for the cradle-to-grave design, build , validation, and support of the specialized test equipment that ensures these flight products and systems perform as intended in their extreme operating environments. The Special Test Equipment (STE) team plays a pivotal role in the realization of Boeing's groundbreaking space initiatives and also supports the entirety of the Boeing Defense and Security product line along with some Boeing Commercial Aviation products. As part of our collective efforts, you will contribute to diverse projects ranging from cutting-edge satellite communication systems to advanced exploration ventures. Your expertise will have a direct impact on crucial missions, such as the development of the Wideband Global SATCOM (WGS) system - a high capacity satellite communications system for the United States Defense Department; the X-37B - an unmanned, reusable spaceplane; the CST-100 Starliner - a spacecraft designed to transport crew to the International Space Station and private space stations of the future, and many more space based missions! Moreover, your contribution will not be limited to Earth's orbit. We also conduct interplanetary missions, like the Lunar Gateway - a small spaceship in orbit around the moon that astronauts will use as a staging point for lunar surface expeditions and trips to Mars. In the ever-evolving arena of space technology, the STE team will also participate in research and development initiatives focusing on futuristic technologies such as advanced propulsion systems, spaceborne telescopes, and spacecraft for asteroid mining and space-based solar power systems. Joining our team means not only contributing to tangible space missions but also shaping the future of space exploration. Here at Boeing, you're not just starting a job; you're advancing your career in ways that will align with your aspirations and passions. It's more than a place to work; it's a place to fulfil your potential and passion for space technology.

Requirements

Bachelor of Science degree in Engineering (with a focus in Electrical, Mechanical or Aeronautical), Computer Science, Data Science, Mathematics, Physics, Chemistry or non-US equivalent qualifications directly related to the work statement
Typically, 2 or more years' related work experience or an equivalent combination of technical education and experience or non-US equivalent qualifications.
Minimum 2 years of professional experience using CAD software
Experience generating drawings and work instructions for technicians
Experience using PLM tools and document release/control practices
Ability to participate in or lead hands-on prototyping and troubleshooting in a lab environment
Ability to obtain a U.S. Security Clearance for which the U.S. Government requires U.S. Citizenship.

Nice To Haves

GD&T Experience
Experience with 3D printing and modeling
Familiarity with common commercial off-the-shelf (COTS) solutions for electronic systems (i.e. connectors, enclosures, etc.)
Familiarity with manufacturing processes and DFMAT
Experience with PCB design, layout, and routing (Cadance and Mentor Xpedition is a plus)
Experience with thermal modeling and analysis
Software/coding experience using LabView, TestStand, C/C#, Python, and MATLAB.
Experience designing automated test systems for power/digital and RF/mixed signal systems.
Knowledge and experience in control, analog, digital, or power supply circuit design.
Experience with electronics laboratory instrumentation to troubleshoot circuit design and hardware manufacturing errors.

Responsibilities

Define mechanical architecture for STE platforms, including enclosures, fixtures, harness routing, mounting and alignment systems, thermal control hardware, vibration/test interfaces, and integration hardware for space‑grade test systems.
Lead hands‑on development from concept through build and test.
Create detailed 3D CAD models and 2D manufacturing drawings, assembly instructions, and technician work instructions to support fabrication, assembly, and acceptance testing.
Perform mechanical analyses and modeling (structural, modal, thermal, tolerance stack‑up, and fit/function) to predict performance and ensure compliance with space and test environment requirements. Use appropriate tools (FEA, thermal simulation, tolerance tools).
Design and implement thermal management solutions for STE and DUT (device under test), including conduction, convection, radiation path design, heat sink/fan selection, and thermal interface materials. Perform thermal simulations and validate with test data.
Lead prototyping activities: machine shop fabrication, sheet metal, additive manufacturing (3D printing), and rapid iteration.
Troubleshoot and refine mechanical designs through hands‑on testing.
Design test fixtures, mechanical interfaces, kinematic mounts, and COTS selections (connectors, fasteners, enclosures, EMI shielding) to support electrical test procedures and instrument integration.
Collaborate with electrical engineers to support PCB mechanical constraints, board standoffs, connectors, and routing. Provide layout guidance for enclosure clearances, cooling, and serviceability. Familiarity with PCB layout and constraints is valuable.
Support development and implementation of automated test systems by integrating mechanical motion stages, switches, sensors, and actuators with control software (LabVIEW, TestStand, Python, C#, etc.).
Design for manufacturability and assembly (DFM/DFMA).
Participate in lab testing and debugging using electronics lab instrumentation to diagnose mechanical‑electrical integration issues, vibration/shock problems, thermal anomalies, and assembly errors.
Prepare and maintain design documentation, drawings, BOMs, and release packages using PLM tools and document control/verification processes.
Provide technical support during production, environmental qualification, and flight‑unit integration. Troubleshoot anomalies discovered during integration, test, delivery, and operational use.
Recommend procurement of mechanical test equipment, tooling, and COTS hardware; evaluate vendors and prepare procurement specifications.
Track project tasks, schedules, and costs using project management tools (e.g., Microsoft Project) to ensure on‑time delivery.