Lead Avionics Mechanical Engineer – Spacecraft & Launch

Firefly Aerospace, Inc.; Austin, Northern (TX, KY); Hybrid; USD 110,000 - 170,000; Full time

Benefits offered by this job

Unlimited PTO

3-month sabbatical for every 5 years

Medical, dental, vision, life, and-dis

Mental health services

Paid military leave

Family planning: $20k

Stock bonuses

Safe Harbor 401(k) matching

$10k home purchase bonus in Cedar Park

Job summary

Firefly Aerospace, Inc. in Austin, TX seeks an experienced Avionics Mechanical Engineer to own advanced electronics packaging and electro-mechanical assemblies for launch vehicles and spacecraft.

You will lead complex designs, analyses, and qualification activities across multidisciplinary teams to ensure mission success. Qualified candidates have 5+ years in aerospace packaging, strong NX/ANSYS skills, and a track record from concept through production, including thermal and vibration analyses

Qualifications

• Bachelor of Science in Mechanical Engineering, Aerospace Engineering, or a related technical field.
• Minimum 5+ years designing high-rel electronics packaging and electro-mechanical assemblies (aerospace/defense preferred).
• 3D CAD design (NX preferred) and GD&T.
• Proven track record from concept through environmental qualification and production.
• Experience with multi-layer PCBA enclosure design and thermal management.
• Strong understanding of structural and thermal calculations for spaceflight.
• Systems-level aerospace knowledge and cross-functional collaboration.
• Manufacturing methods including 5-axis machining, sheet metal, and additive manufacturing.

Responsibilities

• Lead design and architecture of ruggedized electronics packaging for launch vehicles and spacecraft.
• Develop electro-mechanical assemblies for extreme thermal/dynamic environments and EMI/EMC shielding.
• Perform thermal analyses (steady-state, transient, cycling) for space environments.
• Oversee vibration/shock analyses to ensure structural integrity during launch.
• Lead test fixture and ground support equipment design for electronics.
• Drive environmental test campaigns (TVAC, vibration) for product qualification.
• Create CAD models, drawings, and documentation; lead design reviews (PDR/CDR).
• Collaborate with PCB design to optimize mounting, tolerances, and thermal paths.
• Mentor junior/mid engineers and promote design best practices.

Skills

Electronics packaging

Electro-mechanical design

NX CAD

FEA/Ansys

Thermal analysis

Vibration testing

GSE design

System-level aerospace understanding

Mentoring engineers

Education

Bachelor of Science in Mechanical Engineering, Aerospace Engineering, or related field

Tools

NX CAD

ANSYS

GD&T

Job description

Firefly Aerospace, Inc. in Austin, TX seeks an experienced Avionics Mechanical Engineer to own advanced electronics packaging and electro-mechanical assemblies for launch vehicles and spacecraft.

You will lead complex designs, analyses, and qualification activities across multidisciplinary teams to ensure mission success. Qualified candidates have 5+ years in aerospace packaging, strong NX/ANSYS skills, and a track record from concept through production, including thermal and vibration analyses