Lead Propulsion Systems Engineer — Spaceflight Hardware

Front Door Defense; Burlingame (CA); On-site; USD 185,000 - 218,000; Full time

Job summary

Xona seeks a Sr. Mechanical Engineer to lead propulsion hardware design from concept through prototype to flight production at our Burlingame facility for spaceflight.

You will own the mechanical architecture, drive CAD, FEA, and test plans, and collaborate with aerospace teams to deploy reliable hardware. The role demands hands-on prototyping, DFM execution with machinists and vendors, and deep material knowledge for high-temperature, vacuum environments.

Qualifications

• Bachelor's or Master's degree in mechanical engineering.
• Experience leading mechanical hardware design from concept through prototype into production.
• Strong Design for Manufacturability and working with machinists and vendors.
• Expert-level GD&T and tolerance analysis (ASME Y14.5).
• Deep materials knowledge including refractory metals and ceramics.
• Proficiency with CAD (SolidWorks) and finite element modelling for structural and thermal analysis.
• Prototyping-first mindset and hands-on hardware experience.
• Strong problem-solving ability and attention to detail.
• Ability to work collaboratively within multidisciplinary engineering teams.

Responsibilities

• Serve as the lead designer for the propulsion system and supporting hardware.
• Drive Design for Manufacturability (DFM) across several high-precision mechanical components and assemblies working directly with machine shops and specialty vendors.
• Select materials for high-temperature, high-vacuum, and other demanding environments and define standards and material treatments.
• Perform structural and thermal analysis to evaluate margins and ensure survival under launch and operational environments.
• Build, assemble, and iterate on prototype hardware, and support integration into TVAC facilities.
• Develop and execute test plans for prototypes, engineering models, and flight hardware, and troubleshoot mechanical assemblies in the lab.
• Define inspection, acceptance, and assembly procedures that carry the design from prototype into sustained production.
• Support supplier evaluation and selection for mechanical and thermal components.

Skills

GD&T

DFM

SolidWorks

FEM Analysis

Prototyping

Materials Knowledge

Leadership

Vendor Coordination

Structural Analysis

Education

BSc/MSc Mechanical Engineering

Tools

FEA Software

Job description

Xona seeks a Sr. Mechanical Engineer to lead propulsion hardware design from concept through prototype to flight production at our Burlingame facility for spaceflight.

You will own the mechanical architecture, drive CAD, FEA, and test plans, and collaborate with aerospace teams to deploy reliable hardware. The role demands hands-on prototyping, DFM execution with machinists and vendors, and deep material knowledge for high-temperature, vacuum environments.