Mechanical Engineering Lead – Avionics

Firefly Aerospace; United States; On-site; USD 120,000 - 180,000; Full time

Job summary

Firefly Aerospace seeks a qualified Avionics Mechanical Engineer to own complex electronics packaging for launch vehicles and spacecraft. You will lead design architectures, perform thermal and structural analyses, and collaborate with multidisciplinary teams to ensure mission success.

Responsibilities include driving qualification testing, developing CAD models, and mentoring junior engineers while applying rigorous GD&T and manufacturing methods for spaceflight environments.

Qualifications

• Bachelor of Science in Mechanical Engineering or Aerospace Engineering or related technical field.
• 5+ years in high reliability electronics packaging and electromechanical assemblies.
• 3D CAD design with NX preferred and GD&T proficiency.
• Experience taking complex electro-mechanical products from concept through environmental qualification.
• Proficiency with NX CAD and FEA tools (e.g., ANSYS).
• Experience with multi-layer PCBA enclosure design and thermal interfaces.
• Strong thermal/structural calculations, EMI/EMC, shielding, and tolerance stack-ups.
• Knowledge of manufacturing methods for spaceflight environments.

Responsibilities

• Lead design and architecture of ruggedized electronics packaging for PCB assemblies in launch vehicle and spacecraft applications.
• Perform thermal, modal, random vibration, and shock analyses; review and validate results.
• Oversee test fixture and GSE design; lead TVAC campaigns for qualification.
• Drive CAD models, drawings, documentation, and design reviews; present to leadership.
• Collaborate with PCB design teams on mounting strategies, tolerances, and thermal management.
• Mentor junior engineers and establish design best practices; interface with external vendors as needed.

Skills

Rugged electronics packaging

Electro-mechanical design

Thermal management

Education

Bachelor's degree in Mechanical Engineering

Bachelor's degree in Aerospace Engineering

Related technical field

Tools

NX CAD

ANSYS

3D CAD design

Job description

ABOUT 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 lifecycleincluding advanced design rigorous analysis hands on buildintegration 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 applicationsDesign and optimize complex electro mechanical assemblies for extreme thermal and dynamic environments EMIEMC compatibility and radiation resistancePerform and review advanced thermal analyses steady state transient and thermal cycling of electronics in space environmentsPerform and review modal random vibration and shock analyses of electronic assemblies to ensure structural integrity during launchOversee the design of high reliability test fixturing and ground support equipment GSE for launch vehicle and spacecraft electronicsDefine execute and lead vibration shock and thermal vacuum TVAC environmental test campaigns for product qualification and acceptanceDrive the creation of CAD models engineering drawings and technical documentation; lead formal design reviews PDR CDR and present to leadershipPartner closely with the PCB design team to establish mounting strategies keep outs tolerance stack ups connector placement and advanced thermal management solutionsMentor and guide junior and mid level engineers establishing design best practices and reviewing their technical work

QUALIFICATIONS

• Required Bachelor of Science in Mechanical Engineering Aerospace Engineering or a related technical field5 years of professional industry experience designing high reliability electronics packaging and electro mechanical assemblies preferably in aerospace defense or automotive3D CAD design NX preferred and geometric dimensioning and tolerancingProven track record of taking complex electro mechanical products from initial concept through environmental qualification and productionDesired Proficiency with NX CAD and finite element analysis FEA tools such as ANSYSExperience with multi layer PCBA enclosure design including complex thermal interface materials TIMs and CTE analysisStrong understanding of structural and thermal calculations including vent analyses EMIEMC shielding worst case tolerance stack ups bolt pre loads and Steinberg PCB solder joint fatigue life predictionsSystems level understanding of launch vehicle architectures instrumentation interfaces and avionics master networksExpert knowledge of manufacturing methodologies 5 axis CNC machining sheet metal additive manufacturing and materialplating selection for spaceflight environmentsExperience interfacing with external vendors and manufacturing partners to resolve DFM issues and expedite production