Sr. Mechanical Engineer, Ruggedization

Aurelius Systems•San Francisco, CA

2d•Onsite

About The Position

Aurelius Systems is a VC-backed defense tech startup focused on developing autonomous, edge-deployed directed energy systems for counter-UAS, essentially building laser weapons to neutralize drones. The company emphasizes a culture of high output, direct action, and ownership, operating from labs in San Francisco and a manufacturing hub in Detroit, with weekly field testing on a private range. This role is for a Senior Mechanical Engineer to lead the ruggedization efforts for the Archimedes system, with a specific focus on the turret and gimbal subsystems. The engineer will be responsible for ensuring hardware can withstand demanding conditions, including transport, vibration, and weather, and will drive the design, testing, and transition from lab prototype to a field-ready system.

Requirements

5 to 10+ years of experience in mechanical engineering with a focus on real, fielded hardware.
Direct, hands-on experience designing turrets or gimbals for military applications; Remote Weapon Station (RWS) backgrounds are strongly preferred.
Proven track record of leading mechanical design on a system, not just supporting it.
Expert proficiency in CAD software (SolidWorks, Creo, or similar).
Strong background in Finite Element Analysis (FEA) using ANSYS, SolidWorks Simulation, or equivalent, with hands-on application.
Experience planning and executing environmental, vibration, and shock testing on actual hardware.
Solid understanding of materials science, stress analysis, and manufacturing methods (machining, casting, sheet metal).
Experience designing hardware that has been bolted to a vehicle, vessel, or fixed site and has survived demanding conditions.
Ability to think in terms of failure modes before prototyping.
Experience taking a system from CAD through environmental qualification.
BS or MS in Mechanical Engineering, Aerospace Engineering, or a related field (practical experience is valued more than academic institution).

Nice To Haves

Direct experience in directed energy, counter-UAS, or air defense programs.
Experience with slip-ring, rotary joint, and cable management design for continuous-rotation systems.
Experience with vacuum or environmental chamber testing.
Familiarity with EMI/EMC design and shielding.
Active security clearance or the ability to obtain one.
Familiarity with MIL-STD-810, MIL-STD-461, and related qualification standards.

Responsibilities

Mechanical design lead for the turret and gimbal subsystems, encompassing precision pointing structures, slew bearings, drive trains, and stowed-to-deployed transitions.
Lead ruggedization efforts for the entire system, addressing shock, vibration, environmental sealing, and EMI for outdoor and field-deployed scenarios.
Perform stress, vibration, and modal analysis using tools like ANSYS or SolidWorks Simulation.
Engage in hands-on prototyping, coordinate fabrication, and develop test fixtures.
Plan and execute environmental, vibration, shock, and durability testing under real-world field conditions.
Focus on Design for Manufacturing (DFM) and collaborate with suppliers to transition designs from prototype to production-ready.
Select appropriate materials (metals, polymers, composites) considering strength, stiffness, thermal behavior, and EMI compatibility.
Create GD&T drawings, Bills of Materials (BOMs), and assembly documentation compliant with MIL-STD and ITAR requirements.
Collaborate with cross-functional teams (optics, electronics, firmware, controls, laser) during system integration and field testing.