Hardware Engineer
Aurelius Systems•San Francisco, CA
•Onsite
About The Position
We need a Hardware Engineer who can own structural and thermal design for a laser weapon system being built from scratch. You'll run FEA, develop thermal solutions, and drive prototype validation. This isn't a simulation role. You'll be in the lab building things, in the field breaking them, and back at the bench fixing them. Concept through production. Hands on the whole way.
Requirements
- 2 to 8 years in mechanical or hardware engineering in defense, aerospace, or a related field
- Expert in CAD — SolidWorks, Creo, or similar
- Strong FEA background — ANSYS, SolidWorks Simulation
- Thermal analysis experience with CFD and heat transfer software
- Hands on mechanical prototyping and test fixture development
- Experience planning and executing vibration, shock, and environmental testing
- Solid foundation in materials science, stress analysis, and manufacturing methods
Nice To Haves
- Vacuum or environmental chamber testing experience
- Familiarity with laser safety standards and optical alignment fixtures
- Background in EMI/EMC design and shielding
- Security clearance or ITAR compliance experience
Responsibilities
- Develop and validate thermal solutions — passive and active — for high power laser modules including conjugate heat transfer and transient thermal simulations
- Perform stress, vibration, and modal analyses using ANSYS, SolidWorks Simulation, or equivalent and use results to optimize designs for durability, weight, and dynamic loads
- Create and refine CAD models for thermal management and structural prototypes
- Drive hands on prototyping via CNC, additive, or rapid fabrication with an extreme bias toward testing. This includes plan and execute vibration, shock, environmental, and robustness tests under real field conditions
- Conduct DFM reviews to optimize geometry, tolerances, and material selection and work directly with suppliers and fabricators to get designs into production
- Evaluate metals, polymers, and composites for mechanical strength, thermal conductivity, and EMI compatibility
- Generate BOMs, GD&T drawings, and assembly instructions and oversee prototype-to-production transition in compliance with MIL-STD and ITAR requirements
- Partner with optics, electronics, firmware, and controls teams during system assembly, integration, and field testing on our range
Benefits
- Competitive salary and equity
- United Health Care medical, dental, and vision coverage
- Flexible 18 days PTO plus 5 sick days
- Travel to field test events and range days
- Covered daily lunches and office snacks and drinks
- E-bike and scooter stipend up to $500
- Direct access to leadership and real ownership over your work
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What This Job Offers
Job Type
Full-time
Career Level
Mid Level
