Sr HIL Engineer/Test & Automation Engineer

Astra•Alameda, CA

139d•$140,000 - $180,000•Hybrid

About The Position

Astra is building Rocket 4, a high-cadence small-satellite launch vehicle. The Test & Launch team is the common infrastructure layer for the program – we design and operate the test stands, simulation environments, and launch systems that propulsion, avionics, GNC, and structures all depend on. This role sits at the intersection of instrumentation and control, automation software, and systems test. You will design DAQ and control architectures for test stands across the program, write the software that makes those stands run safely and repeatably, and work directly with engineering teams to define what test infrastructure they need and build it. One of the near-term workstreams for this role is the Launch System Simulator (LSS), a hardware-in-the-loop environment that runs the full avionics stack, flight software, and GNC algorithms against real-time plant models. The LSS needs an owner who can define its architecture, build out the simulation infrastructure, and integrate it into the broader test program. Beyond LSS, the role expands into I&C design and commissioning across 20+ test stands on the development roadmap. This is not a desk job. You will be in the lab, on the test stand, at the facility. You will write control logic, terminate wiring, commission sensors, troubleshoot data pipelines during a test campaign, and eventually support launch operations.

Requirements

4+ years of experience in test engineering, instrumentation & control, or systems test in aerospace, defense, automotive, or a hardware-intensive field.
Hands-on experience designing and commissioning DAQ and control systems: sensor selection, signal conditioning, I/O architecture, real-time control platforms.
Strong controls programming background: PLC/IEC 61131-3, structured text, state machines, interlock logic. Beckhoff TwinCAT preferred.
Proficient in Python for data processing, test automation, and tooling.
Experience with hardware-in-the-loop (HIL) simulation: real-time plant models, simulation framework integration, test case development.
Comfortable with the full hardware lifecycle: you have taken a test stand from concept through commissioning and operated it during a test campaign.
Strong communicator across disciplines. You have worked directly with software, avionics, or propulsion teams and translated between hardware and software requirements.
Ability to work on-site in Alameda, CA with periodic travel to test sites and Cape Canaveral.

Nice To Haves

Software-in-the-loop (SIL) simulation experience: FSW regression frameworks, plant model integration, test case development without hardware in the loop.
Beckhoff EtherCAT ecosystem: TwinCAT 3, EL series I/O terminals, real-time control.
Real-time plant model development for HIL simulation: Simulink Real-Time, Speedgoat, NI VeriStand, or custom frameworks.
Experience with flight software or avionics test: FSW regression frameworks, bus simulation (MIL-STD-1553, SpaceWire, UART/SPI/I2C), fault injection.
Industrial fieldbus and protocol experience: EtherCAT, CAN bus, Modbus, Profinet.
Familiarity with data pipeline tools: InfluxDB, Grafana, Parquet, TDMS, SQL, or time-series database architectures.
Propulsion or hazardous fluid system experience: LOX/LN2/GN2 handling, high-pressure pneumatics, cryogenic instrumentation.
Electrical control cabinet design: layout, grounding, EMI mitigation, wire routing, panel fabrication.
Startup or high-tempo development environment (SpaceX, Relativity, Firefly, Joby, Zoox, Anduril, Cruise, or similar).
dSPACE, Speedgoat, or NI VeriStand platform experience.

Responsibilities

Work with propulsion, avionics, and software teams to design DAQ and control system architectures for test stands across the program: instrumentation plans, I/O lists, sensor selection, signal conditioning, control cabinet layout, wiring schematics.
Write and commission control logic for test stand automation: sequencing, safety interlocks, abort logic, and operator interfaces. Beckhoff TwinCAT / structured text, Python, and whatever else gets the job done.
Own the Launch System Simulator from architecture through delivery: select the HIL hardware platform, build real-time plant models (propulsion, GNC, avionics), define the simulation interface to flight software, and integrate fault injection and Monte Carlo test campaigns.
Partner with ground software teams on data pipeline architecture: understanding the full path from DAQ hardware through storage, processing, and visualization well enough to define requirements and troubleshoot during test campaigns.
Work with propulsion, avionics, GNC, and flight software teams to design and build test infrastructure: defining requirements, validating acceptance criteria, and commissioning new stands through ORR.
Support active test campaigns at Castle (Chiron engine hot-fire) and Orion (upper stage component test). Travel to Cape Canaveral for launch campaign support.
Document everything: P&IDs, wiring diagrams, software architecture, commissioning procedures, and test reports in Confluence.