Senior Propulsion Development Engineer, Test Stand

True Anomaly•Denver, CO

20h•Onsite

About The Position

As a Senior Propulsion Development Engineer at True Anomaly, you will be the hands-on design and build lead for the ground systems and facility infrastructure that make our new Denver Front Range propulsion test stand operational. You will create detailed designs for hypergolic propellant feed systems, GSE, fluid system plumbing, structural hardware, and supporting facility systems — then see those designs through fabrication, installation, and commissioning. Working with highly toxic and reactive propellants demands an uncompromising approach to design rigor and safety, and you will help design the systems that meet that standard for the facility. This is a builder's role: you will leave a lasting mark on a test capability that will power True Anomaly's propulsion programs for years to come.

Requirements

Bachelor's degree in Mechanical, Aerospace, or Chemical Engineering.
8+ years of professional experience in the design and build of propulsion ground systems, test facility hardware, or high-pressure fluid systems for aerospace or defense applications.
Demonstrated hands-on experience designing fluid systems for hypergolic, toxic, or highly reactive propellants, including material compatibility, secondary containment, and emergency safing provisions.
Proficiency with 3D CAD tools (NX, SolidWorks, or equivalent) and production of fully detailed engineering drawings for fabrication.
Experience developing P&IDs for propulsion or chemical process systems and working with pressure system design codes (ASME B31.3 or equivalent).
Solid understanding of pressure system safety requirements including proof, burst, and leak test margins, and relief device sizing.
Demonstrated ability to take a design from concept through fabrication, installation, and commissioning.
Excellent written and verbal communication skills, including the ability to produce clear technical documentation and interface with safety and regulatory stakeholders.

Nice To Haves

Direct experience designing and building hypergolic propellant test stands or ground fluid systems for spacecraft or launch vehicle programs.
Familiarity with Hydrazine, NTO, MMH, UDMH, or red fuming nitric acid (RFNA) handling systems and the associated material, cleaning, and personal protective equipment requirements.
Experience coordinating with AHJs, fire marshals, or environmental regulators on permitting for hazardous chemical storage or operations.
Background in structural analysis or FEA for test stand structures and pressure vessels.
Familiarity with instrumentation and control system interfaces for propulsion test: pressure transducers, flow meters, thermocouples, automated valve control, and emergency shutdown systems.
Experience with cleaning, passivation, and cleanliness verification for hypergolic-compatible fluid systems.
Familiarity with Colorado Front Range permitting, zoning, or environmental requirements for toxic propellant storage and operations.
Active DoD security clearance (Secret or above), or ability to obtain one.

Responsibilities

Lead the detailed mechanical design of hypergolic propellant feed systems, including propellant storage vessels, transfer lines, fill and drain assemblies, valve configurations, and pressurization circuits for a new test stand.
Select fluid system components and assemblies compatible with hypergolic propellants (NTO, MMH, UDMH, or similar), including sizing, material selection, seal compatibility, leak containment, and pressure ratings.
Develop and own P&IDs for hypergolic propellant and pressurant systems; ensure designs incorporate appropriate redundancy, isolation, and emergency safing capabilities.
Design propellant offload, storage, and transfer infrastructure including secondary containment, vent and drain routing, and neutralization provisions.
Integrate hypergolic system designs with fire suppression, facility exhaust and scrubbing systems, personnel protection provisions, and facility control interfaces.
Apply and enforce applicable design standards and material compatibility requirements throughout all hypergolic system designs.
Design the primary test stand structure including thrust measurement systems, engine/thruster mount interfaces, and load paths for anticipated thrust levels and dynamic loads.
Detail mechanical designs for run tank assemblies, GSE carts, propellant conditioning systems, and ancillary facility hardware.
Produce fully detailed CAD models and engineering drawings suitable for fabrication, procurement, and third-party review.
Conduct or coordinate structural and pressure system analyses including FEA, pressure budget calculations, and proof and burst margin verification.
Design for maintainability, access, and operational safety — ensuring that technicians can safely configure, operate, and service all systems.
Develop fabrication packages including drawings, material specifications, weld and joining requirements, and acceptance criteria for test stand hardware.
Identify and qualify vendors for fabricated components, pressure vessels, specialty valves, instrumentation, and other long-lead hardware; provide technical oversight throughout procurement.
Support and oversee the fabrication, assembly, and installation of designed systems; resolve fabrication anomalies and nonconformances.
Define and execute acceptance test requirements for delivered hardware, including proof pressure testing, leak checks, and functional verification.
Develop GSE and tooling needed to safely handle, install, and service hypergolic system components.
Serve as the design authority for hypergolic system safety features; ensure all designs comply with applicable OSHA, EPA, NFPA, and DoD standards for toxic and reactive propellant handling.
Contribute to facility hazard analyses (PHA, FMEA) and support development of operating procedures from a design perspective, ensuring procedures accurately reflect as-built system configuration.
Coordinate with local authorities having jurisdiction (AHJ), fire marshal, and environmental regulators on facility design reviews and permitting requirements related to hypergolic propellant storage and operations.
Establish and document material compatibility requirements and cleaning and passivation standards for all wetted components.
Lead the mechanical commissioning of hypergolic facility systems, including system cleanliness verification, pressure testing, leak checks, and functional checkouts.
Maintain as-built documentation throughout facility construction and commissioning; ensure configuration control of all facility systems.
Provide ongoing design support during early test operations, including hardware modifications and continuous improvement initiatives.