Mechanical Engineer | Solar Array Deployable Structures

Cowboy Space Corp.

7d•$100,000 - $300,000•Onsite

About The Position

As a Mechanical Engineer – Solar Array Deployable Structures, you will be the responsible engineer for the large deployable structure that supports and positions our solar array. This is a mechanisms-first, hands-on role: you will architect and own the deployment mechanism along with its actuation, latching, and stowage, and the structural design that makes a very large deployed structure stiff, light, and reliable. You will own this hardware end to end, from concept and analysis through the ground testbeds used to prove it out, qualification, and on-orbit deployment. Deploying a very large structure reliably is the central challenge of the role. You will work closely with structures, manufacturing, GN&C, power, avionics, propulsion, and software teams to deliver an integrated array. We’re looking for a strong deployable-mechanism background paired with solid structural analysis skills—someone who can move quickly, iterate often, and take full ownership of hardware that directly determines whether our spacecraft gets the power it needs on orbit.

Requirements

BS or MS in Mechanical Engineering, Aerospace Engineering, or a related field
3+ years of experience designing and analyzing deployable mechanisms and/or precision mechanical hardware in aerospace or other high-performance environments
Strong mechanism fundamentals: kinematics, actuation, springs and stored energy, motors and drives, bearings, latches, tribology, and deployment reliability
Solid structural fundamentals: stiffness, buckling and stability, strength, and structural dynamics of slender or lightweight structures
Hands-on experience building and testing mechanisms, including deployment testing
Experience taking hardware from concept through build and test, with hands-on integration and test experience
Proficiency with CAD (e.g., NX, SolidWorks, or similar)
Experience working in fast-paced, hardware-focused development environments

Nice To Haves

Direct experience designing deployable booms, masts, or large deployable structures for solar arrays, antennas, or similar
Experience with composite structures—design, analysis, layup, bonding, and joint design—and composite fabrication and test
Experience with large or flexible-blanket solar arrays, including deployment, tensioning, and stowage
Experience designing and operating gravity-offload or deployment test rigs for large or long structures
Experience designing for space environments (thermal, vibration, vacuum) and background in spacecraft mechanisms, structures, or deployables
Familiarity with structural dynamics of large flexible structures and their interaction with GN&C (low-frequency modes, pointing, jitter)
Experience with space-rated lubrication, tribology, and mechanism qualification
Knowledge of aerospace standards (MIL-SPEC, NASA-STD, ECSS) and spaceflight hardware qualification and acceptance margins
Startup or early-stage hardware experience; comfort operating with significant technical ambiguity

Responsibilities

Own the design of the deployable structure’s mechanism from concept through flight, including actuation, deployment sequencing, latching and locking at full extension, and stowage and launch restraint.
Design and analyze the deployment kinematics, actuation, synchronization, and end-of-travel latching, and quantify deployment reliability, force/torque margin, and jam resistance.
Design mechanism details—bearings, guides, drives, dampers, and release devices—with attention to tribology, space-rated lubrication, and repeatable, low-shock deployment.
Perform structural analysis of the deployed and stowed structure—deployed stiffness and fundamental frequency, buckling and stability, strength, and thermal distortion—and design to meet stiffness and pointing requirements.
Design the interfaces to the solar array and its supporting hardware, balancing structural stiffness against operational loads and dynamics.
Design, build, and operate ground testbeds and dev rigs, including gravity-offload deployment fixtures for a very large structure, to characterize the mechanism, validate deployment, and de-risk the flight design.
Develop and execute deployment, life/cycle, structural static/modal, vibration, thermal-vacuum, and qualification/acceptance test programs to verify flight-worthiness.
Drive design-for-manufacturing of long, precision structural elements—tolerances, straightness, and repeatability—and work with suppliers to ensure high-quality, scalable production.
Author and maintain drawings, interface control documents, analysis reports, test procedures, and release/configuration records.
Diagnose and resolve mechanism and structural anomalies during integration and test, applying root-cause analysis and implementing corrective actions.
Partner with structures, GN&C, power, avionics, propulsion, and software teams to ensure the array integrates seamlessly within the overall spacecraft architecture, including low-frequency flexible-body dynamics.
Embrace a fast-paced development environment, driving quick design cycles, hardware builds, and test campaigns to accelerate the program schedule.