Lead Mechatronics Engineer

Astra Core-X; Denver (CO); On-site; USD 120,000 - 180,000; Full time

Benefits offered by this job

Medical Insurance

Dental Insurance

Life Insurance

Short-term Disability

Long-term Disability

401(k) Retirement Plan

Job summary

Astra Core-X in Denver is seeking a talented mechanical design engineer to advance actuation mechanisms and control surfaces for aerospace propulsion systems.

You will design, validate, and integrate mechanical actuation with control algorithms, oversee prototype fabrication, and conduct ground and flight tests to ensure performance and reliability. Security clearance may be required for program work.

Qualifications

• Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, Mechatronics, or related field.
• 3+ years of experience in design and development of actuation systems, mechanisms, or aerodynamic surfaces—preferably in aerospace or defense.
• Proficiency with 3D CAD software and FEA tools.
• Experience with actuator selection, integration, and testing.

Responsibilities

• Design, develop, and optimize mechanical actuation systems for flight control surfaces.
• Collaborate with guidance, navigation, and control (GNC) engineers to ensure seamless integration of hardware with control algorithms.
• Perform structural and dynamic analysis (using FEA and other tools) to verify integrity and performance of control surfaces and mechanisms under operational loads and environments.
• Select appropriate materials, actuators (electric, pneumatic, hydraulic), and sensors for robust, lightweight, and reliable system performance.
• Develop CAD models, detailed drawings, and specifications for manufacturing.
• Oversee prototype fabrication, assembly, and integration of control mechanism hardware.
• Plan and execute ground and flight tests to validate mechanical performance and actuation response.
• Support troubleshooting, root cause analysis, and design improvements throughout development and production.
• Document design decisions, test results, and provide technical reports to project stakeholders.
• Ensure compliance with military standards, safety, and quality requirements.

Skills

Actuation systems design

Structural/dynamic analysis

Control integration

Hardware troubleshooting

Education

Bachelor's degree in Mechanical/Aerospace/Mechatronics

Tools

SolidWorks

CATIA

Creo

ANSYS

Job description

Clearance: US Citizenship Required (ITAR/DoW Programs)

About the Company

Astra Core-X (ACX) is developing affordable and capable tactical propulsion technologies for the defense of the US and our allies. ACX is rapidly bringing this capability to market by incorporating the latest manufacturing processes and technological advancements, with solid financial backing, under the guidance and support of world-class industry experts and leading research institutions.

Job Description

We are seeking a talented and detail-oriented engineer to join our mechanical design engineering team, specializing in the development of control system mechanisms and control surfaces. The successful candidate will be responsible for the design, integration, and validation of actuation mechanisms and aerodynamic surfaces critical to aerospace vehicle maneuverability, stability, and performance.

Key Responsibilities

• Design, develop, and optimize mechanical actuation systems for flight control surfaces (e.g., fins, canards, thrust vectoring vanes).
• Collaborate closely with guidance, navigation, and control (GNC) engineers to ensure seamless integration of hardware with control algorithms.
• Perform structural and dynamic analysis (using FEA and other tools) to verify integrity and performance of control surfaces and mechanisms under operational loads and environments.
• Select appropriate materials, actuators (electric, pneumatic, hydraulic), and sensors for robust, lightweight, and reliable system performance.
• Develop CAD models, detailed drawings, and specifications for manufacturing.
• Oversee prototype fabrication, assembly, and integration of control mechanism hardware.
• Plan and execute ground and flight tests to validate mechanical performance and actuation response.
• Support troubleshooting, root cause analysis, and design improvements throughout development and production.
• Document design decisions, test results, and provide technical reports to project stakeholders.
• Ensure compliance with military standards, safety, and quality requirements.

Qualifications

• Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, Mechatronics, or related field.
• 3+ years of experience in design and development of actuation systems, mechanisms, or aerodynamic surfaces—preferably in the aerospace or defense sector.
• Proficiency with 3D CAD software (e.g., SolidWorks, CATIA, Creo) and FEA tools (e.g., ANSYS).
• Strong understanding of kinematics, dynamics, and control of mechanical systems.
• Experience with actuator selection, integration, and testing (servo motors, hydraulic actuators, etc.).
• Excellent communication skills and ability to work in multidisciplinary teams.
• Experience with environmental testing (vibration, thermal, shock).
• Hands-on experience with rapid prototyping and hardware troubleshooting.
• Familiarity with flight test instrumentation and data analysis.
• U.S. Citizenship and ability to obtain security clearance required.

Preferred Skills

• Master’s or PhD degree in Mechanical Engineering, Aerospace Engineering, Mechatronics, or related field.
• 10+ years of experience in design and development of actuation systems, mechanisms, or aerodynamic surfaces—preferably in the aerospace or defense sector.
• Strong familiarity with supersonic aerodynamics, flight control, and system integration
• Knowledge of MIL-STD specifications and defense qualification processes.
• Active US government security clearance

Compensation

The annual base salary range for this role is $120K-$180K, depending on experience and scope. ACX offers a comprehensive benefits package that includes group Medical, Dental, Life, and Short and Long-Term disability coverage from day one. We also offer a generous 401(k) Retirement Savings Plan with a Company match. Every role at ACX is bonus eligible.

ACX is committed to full compliance with applicable anti-discrimination laws. We are an equal opportunity employer and value diversity at our company. We strive to create an inclusive work environment and will not discriminate on the basis of race, religion, color, national origin, gender, sexual orientation, age, marital status, veteran status, or disability status.