Mechanical Engineering Lead - Avionics

Firefly Aerospace; Austin (TX); On-site; AUD 90,000 - 130,000; Full time

Benefits offered by this job

Health, dental & vision plans

Relocation benefits

Educational reimbursement

Flexible PTO

Job summary

Firefly Aerospace in New South Wales seeks an experienced Avionics Mechanical Engineer to design rugged electronics packaging for launch vehicles and spacecraft.

You will lead design efforts, perform thermal and vibration analyses, mentor junior engineers, and collaborate with cross‑functional teams to ensure mission success in a fast‑paced aerospace environment.

Qualifications

• BS in Mechanical or Aerospace Engineering or related field.
• 5+ years in high‑reliability electronics packaging and electro‑mechanical assemblies (aerospace/defense preferred).
• Proficiency with NX CAD; GD&T experience.
• Proven track record from concept to environmental qualification and production.
• Experience interfacing with external vendors for DFM and production support.

Responsibilities

• Lead design and architecture of rugged electronics packaging and structural components for launch vehicles and spacecraft.
• Design and optimize electro‑mechanical assemblies for extreme thermal/dynamic environments and EMI/EMC shielding.
• Perform advanced thermal analyses (steady‑state to thermal cycling) for space electronics.
• Conduct modal, random vibration, and shock analyses on electronic assemblies.
• Oversee high‑reliability test fixturing and ground support equipment design.
• Lead vibration, shock and TVAC test campaigns for product qualification/acceptance.
• Create CAD/models, drawings and documentation; lead design reviews (PDR/CDR).
• Collaborate with PCB design team on mounting strategies and thermal management.

Skills

3D CAD (NX)

Geometric dimensioning & tolerancing

Education

BSc Mechanical or Aerospace Engineering

Tools

ANSYS

Job description

About Firefly Aerospace

Firefly Aerospace is a space and defense technology company that enables our world to launch, land, and operate in space – anywhere, anytime. As the partner of choice for critical space missions, Firefly is the only commercial company to launch a satellite to orbit with 24-hour notice and the only company to achieve a successful Moon landing. Our launch vehicles, lunar landers, and orbital vehicles provide government and commercial customers with full mission services from low Earth orbit to the Moon and beyond. Headquartered in north Austin, Texas, Firefly is looking for passionate, hardworking innovators to join our team and help fuel our successful trajectory into space.

About Firefly Aerospace

Firefly Aerospace is a space and defense technology company that enables our world to launch, land, and operate in space – anywhere, anytime. As the partner of choice for critical space missions, Firefly is the only commercial company to launch a satellite to orbit with 24-hour notice and the only company to achieve a successful Moon landing. Our launch vehicles, lunar landers, and orbital vehicles provide government and commercial customers with full mission services from low Earth orbit to the Moon and beyond. Headquartered in north Austin, Texas, Firefly is looking for passionate, hardworking innovators to join our team and help fuel our successful trajectory into space.

About Firefly Aerospace

Firefly Aerospace is a space and defense technology company on a mission to reliably and repeatedly launch, land, and operate space systems from Earth to the Moon and beyond. As the partner of choice for critical space missions, Firefly is the first commercial company to launch a satellite to orbit with 24-hour notice and the first company to achieve a successful Moon landing. Headquartered in north Austin, Texas, Firefly is looking for passionate, hardworking innovators to join our team and help fuel our successful trajectory into space.

Summary

Firefly Avionics Mechanical Engineers leverage their creative design and deep industry experience to develop electronics enclosures, mechanical components, integration hardware, tooling, and test fixtures for launch vehicles. As the lead, you will be expected to own complex avionics subsystems, lead design architectures, and mentor junior engineers. Qualified candidates will be responsible for the full product lifecycle—including advanced design, rigorous analysis, hands‑on build/integration, and qualification testing. You will be a key technical voice within the avionics team and will collaborate heavily with multidisciplinary teams across the company to ensure mission success.

Responsibilities

• Lead design and architecture of ruggedized electronics packaging and structural components for PCB assemblies used in launch vehicle and spacecraft applications.


• Design and optimize complex electro‑mechanical assemblies for extreme thermal and dynamic environments, EMI/EMC compatibility, and radiation resistance.


• Perform and review advanced thermal analyses (steady‑state, transient, and thermal cycling) of electronics in space environments.


• Perform and review modal, random vibration, and shock analyses of electronic assemblies to ensure structural integrity during launch.


• Oversee the design of high‑reliability test fixturing and ground support equipment (GSE) for launch vehicle and spacecraft electronics.


• Define, execute, and lead vibration, shock, and thermal vacuum (TVAC) environmental test campaigns for product qualification and acceptance.


• Drive the creation of CAD models, engineering drawings, and technical documentation; lead formal design reviews (PDR, CDR) and present to leadership.


• Partner closely with the PCB design team to establish mounting strategies, keep‑outs, tolerance stack‑ups, connector placement, and advanced thermal management solutions.


• Mentor and guide junior and mid‑level engineers, establishing design best practices and reviewing their technical work.

Basic Qualifications

• Bachelor of Science in Mechanical Engineering, Aerospace Engineering, or a related technical field.


• 5+ years of professional industry experience designing high‑reliability electronics packaging and electro‑mechanical assemblies (preferably in aerospace, defense, or automotive).


• 3D CAD design (NX preferred) and geometric dimensioning and tolerancing.


• Proven track record of taking complex electro‑mechanical products from initial concept through environmental qualification and production.

Preferred Qualifications

• Proficiency with NX CAD and finite element analysis (FEA) tools such as ANSYS.


• Experience with multi‑layer PCBA enclosure design, including complex thermal interface materials (TIMs) and CTE analysis.


• Strong understanding of structural and thermal calculations, including vent analyses, EMI/EMC shielding, worst‑case tolerance stack‑ups, bolt pre‑loads, and Steinberg PCB solder joint fatigue life predictions.


• Systems‑level understanding of launch vehicle architectures, instrumentation interfaces, and avionics master networks.


• Expert knowledge of manufacturing methodologies (5‑axis CNC machining, sheet metal, additive manufacturing) and material/plating selection for spaceflight environments.


• Experience interfacing with external vendors and manufacturing partners to resolve DFM issues and expedite production.

Firefly offers outstanding benefits for our employees, including generous health, dental and vision plans with low plan deductibles, parental leave, relocation benefits, educational reimbursement, short term disability, and flexible PTO options.

To conform to U.S. Government space technology export regulations, including the International Traffic in Arms Regulations (ITAR) you must be a U.S. citizen, lawful permanent resident of the U.S., protected individual as defined by 8 U.S.C. 1324b(a)(3), or eligible to obtain the required authorizations from the U.S. Department of State.

Firefly Aerospace, Inc. is an Equal Opportunity Employer; employment with Firefly is governed based on merit, competence and qualifications and will not be influenced in any manner by race, color, religion, gender, national origin/ethnicity, veteran status, disability status, age, sexual orientation, gender identity, marital status, mental or physical disability or any other legally protected status.