About this role
Pulse Space Inc. develops advanced photonics and high-power laser systems for industrial, defense, and scientific applications. Our team drives innovation in kW-class fiber laser architectures, beam combining techniques, and next-generation directed-energy platforms.
We are seeking a Senior Mechanical Design Engineer to lead the design, analysis, and integration of mechanical systems for our satellite platforms and laser payloads. This role requires both creative problem-solving and rigorous engineering discipline — you will develop hardware from initial concept through qualification testing and flight production. You will collaborate with optical, electrical, thermal, and systems engineers to deliver space-qualified mechanical systems that enable our mission-critical payloads.
In this role, you will
- Design satellite structural assemblies, payload housings, and precision optomechanical mounts using CREO or equivalent 3D CAD software
- Perform structural analysis (static, dynamic, modal) and thermal analysis to ensure designs meet launch loads, on-orbit environments, and operational requirements
- Design deployable mechanisms and articulation assemblies with emphasis on reliability, mass efficiency, and performance in the space environment
- Develop thermal management architectures including conductive paths, radiators, heat pipes, and interface designs to maintain optical and electronic components within operating limits
- Apply GD&T principles to drawings and models to ensure manufacturability, inspectability, and assembly tolerance stack-up closure
- Drive design for manufacturing (DFM) and design for assembly (DFA) — optimize part count, standardize fasteners, reduce process complexity, and enable high-rate production
- Select materials, coatings, and surface treatments appropriate for space environments: outgassing requirements, thermal cycling, radiation exposure, and micrometeorite resistance
- Build and execute qualification test plans: vibration, shock, thermal vacuum, and functional performance testing to validate designs against requirements
- Work closely with optical engineers to design kinematic mounts, alignment features, and optomechanical interfaces that maintain beam quality and pointing accuracy
- Support integration and test activities, troubleshoot hardware issues, and implement design improvements based on test data and on-orbit performance
What you bring
- B.S. or higher in Mechanical Engineering, Aerospace Engineering, or closely related discipline
- 5+ years of hands-on experience designing mechanical systems for space, defense, or high-reliability applications
- Proficiency in 3D CAD software (CREO strongly preferred; NX, SolidWorks, or similar also considered)
- Strong understanding of mechanical engineering fundamentals: stress analysis, fatigue, fracture mechanics, heat transfer, and dynamics
- Experience with finite element analysis (FEA) tools for structural and thermal simulation (e.g., Ansys, Nastran, Abaqus, or equivalent)
- Working knowledge of geometric dimensioning and tolerancing (GD&T) per ASME Y14.5
- Familiarity with space environment constraints: vacuum, thermal cycling, radiation, launch loads, and material compatibility
- Demonstrated ability to own hardware from concept through production, including design trades, analysis, testing, and documentation
- Strong communication skills and ability to work effectively in cross-functional teams
What will set you apart
- M.S. in Mechanical Engineering or Aerospace Engineering
- Experience designing flight hardware for space vehicles or satellite payloads that have flown or been qualified for flight
- Hands-on experience with precision optomechanical systems: kinematic mounts, athermalization techniques, alignment methods, and stability requirements
- Background in deployable mechanisms (solar arrays, antennas, booms) or pointing/articulation systems (gimbals, scan mirrors, reaction wheels)
- Knowledge of composite materials, laminate analysis, and composite manufacturing processes
- Experience with thermal control design: heat pipes, phase-change devices, MLI blankets, radiator sizing, and thermal interface materials
- Familiarity with additive manufacturing (DMLS, SLM) for space applications and design for additive manufacturing principles
- Track record of taking hardware from early prototypes to high-rate production in aerospace or defense programs
- Experience with scripting or programming (Python, MATLAB) for design automation, parametric studies, or data analysis
- Active U.S. security clearance or eligibility to obtain one is a plus
What we offer
- Competitive salary and equity participation commensurate with experience
- Comprehensive benefits: health, dental, vision, and 401(k) with company match
- The chance to work on state-of-the-art laser systems with tangible real-world impact
- A collaborative, fast-paced R&D culture that values technical excellence
- Professional development support including conference travel and continuing education
- Relocation assistance available for qualified candidates