Junior R&D Engineer

PDW • Huntsville, AL

1d • Onsite

About The Position

Now, we’re entering a new phase of growth and are looking for Junior R&D Engineer to support the rapid development, prototyping, integration, and testing of new technologies, subsystems, and product concepts. This is a highly hands-on engineering role intended for an individual who enjoys building and testing hardware while developing stronger mechanical design, CAD, prototyping, and engineering analysis skills. Working with guidance from senior engineers, the Junior R&D Engineer will help turn early concepts into functional prototypes, execute testing, document results, and iterate designs based on real-world performance.

Requirements

• Bachelor's degree in Mechanical Engineering, Engineering Technology, or a technically related field; or equivalent combination of technical education and relevant hands-on engineering experience.
• Experience with mechanical fabrication, prototype development, assembly, or testing.
• Working knowledge of 3D CAD software such as SolidWorks or similar software.
• Experience with additive manufacturing, including FDM and/or SLS technologies.
• Strong mechanical aptitude and demonstrated hands-on problem-solving ability.
• Ability to use common hand tools, measurement equipment, and fabrication equipment.
• Ability to follow engineering direction, test procedures, and standard operating procedures while completing assigned tasks with increasing independence.
• Ability to clearly document technical work, test configurations, results, and conclusions.
• Ability and willingness to learn new engineering tools, manufacturing processes, and test methods.
• Must have the ability to obtain and maintain a U.S. Security Clearance.

Nice To Haves

• Experience designing parts specifically for additive manufacturing.
• Experience with machining, sheet metal, composites, injection molding, or other manufacturing processes.
• Experience designing and building test fixtures and assembly tooling.
• Experience performing mechanical or electromechanical testing and documenting results.
• Experience with basic electronics integration, wiring, connectors, and mechanical packaging of electronics.
• Experience with UAV aircraft, FPV systems, robotics, or other electromechanical systems.

Responsibilities

• Create and modify 3D CAD models for prototype components, assemblies, test fixtures, and lab hardware.
• Modify existing designs based on prototype fit checks, testing results, manufacturing feedback, and engineering direction.
• Perform basic tolerance analysis and apply appropriate dimensions and clearances to prototype components.
• Create and compare design concepts and communicate the advantages, disadvantages, and risks associated with each approach.
• Develop increasing proficiency in designing components for additive manufacturing, machining, and other applicable manufacturing processes.
• Translate engineering concepts and CAD designs into functional prototypes.
• Build, modify, assemble, and troubleshoot mechanical and electromechanical prototype systems.
• Use additive manufacturing, machining, hand fabrication, and other rapid-prototyping methods to support development activities.
• Design and fabricate test fixtures, assembly fixtures, jigs, adapters, and other development tools.
• Support electronics integration including component mounting, mechanical final assembly, cable routing, and basic wiring.
• Perform prototype fit checks and identify mechanical interference, assembly, tolerance, and serviceability issues.
• Work directly with engineers to rapidly iterate prototype designs based on build and test results.
• Execute mechanical, environmental, functional, and system-level testing as applicable.
• Accurately record test configurations, procedures, observations, measurements, failures, and results.
• Identify failure modes and assist with root-cause investigations.
• Recommend design or process improvements based on test results and observed performance.
• Generate concise engineering test reports documenting test objectives, configuration, methodology, results, conclusions, and recommended next steps.
• Maintain technical ownership and proficiency with R&D additive-manufacturing equipment, including SLS and FDM systems.
• Prepare, operate, maintain, troubleshoot, and calibrate additive-manufacturing equipment.
• Develop and document repeatable printing, post-processing, maintenance, and calibration procedures.
• Evaluate new materials, print parameters, equipment, and processes that improve prototype quality.
• Maintain an organized and functional R&D prototyping environment.
• Assist with maintaining appropriate prototype materials, tools, equipment, spare parts, and consumables.
• Help continuously improve R&D lab processes, equipment capabilities, and development workflows.

Benefits

• Comprehensive BCBS medical, dental, and vision coverage; 80% sponsored by the company.
• Safe Harbor 401(K) with company match.
• Paid Parental Leave.
• On-site gym at our Huntsville, AL and Denver, CO locations.
• Employer provided life insurance.
• Robust Employee Assistance Program (EAP).
• A work environment that encourages teamwork and innovation.
• Competitive salary, generous paid time off (PTO), and flexible leave options.

What This Job Offers

• Job Type: Full-time
• Career Level: Entry Level