Opto-Mechanical Engineer – Satellite Imaging Group

U.S. Fusion Energy; Southbridge (MA); On-site; USD 120,000 - 160,000; Full time

Job summary

AOS is seeking an Opto-Mechanical Design Engineer to develop and test precision optical assemblies for satellite imaging platforms. You will collaborate with optical, mechanical, and systems teams to ensure rugged, thermally stable designs that survive launch and operate reliably in space.

The role emphasizes tolerance analysis, FEA, and integration with test programs to validate performance against simulations. Strong background in opto-mechanical design is essential.

Qualifications

• Degree in Mechanical or Aerospace Engineering required.
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Responsibilities

• Design precision opto-mechanical assemblies for space-based telescopes and mounts.

Skills

3D CAD

FEA analysis

GD&T

Thermal analysis

Opto-mechanical design

Education

Bachelor’s or Master’s in Mechanical/Aerospace Engineering

Tools

SolidWorks/Creo/NX

ANSYS/NASTRAN

Job description

Opto-Mechanical Engineer – Satellite Imaging Group

Opto-Mechanical Design Engineers at AOS play a key role in developing designs for advanced optical systems for space payloads and the special tools, fixtures, and equipment needed to produce and test them. AOS makes optical assemblies for payloads used in Earth imaging, optical communications and scientific research. In this role, your responsibilities will include developing conceptual models and completing designs through prototyping and final development. Qualified candidates must be familiar with tolerancing components and systems to micron-level dimensions and understanding how physical tolerances result in optical regime performance impact. Mechanical Design engineers work closely with optical engineers, system level engineers and manufacturing staff to evaluate and ensure that designs can be made reliably and function as predicted by advanced simulations and tests.

We are seeking a highly motivated Opto-Mechanical Design Engineer to support the design, analysis, integration, and testing of precision optical systems for satellite-based imaging platforms. This role focuses on the development of rugged, lightweight, thermally stable opto-mechanical assemblies capable of surviving launch environments and operating reliably in space. The ideal candidate combines strong mechanical engineering fundamentals with a deep understanding of optical system performance and environmental constraints unique to aerospace applications.

Key Responsibilities

• Design precision opto-mechanical assemblies for space-based telescopes, including mirrors, mounts, structures, and alignment mechanisms
• Develop lightweight, thermally stable structures optimized for launch loads and on-orbit performance
• Perform tolerance analyses to ensure optical performance under thermal, mechanical, and dynamic environments
• Conduct structural, thermal, and vibration analyses using FEA tools
• Support optical alignment strategy development and error budgeting in collaboration with optical engineers
• Select materials compatible with space environments (CTE matching, outgassing, radiation, cryogenic performance, etc.)
• Generate detailed engineering drawings, specifications, and documentation in accordance with aerospace standards
• Support prototype builds, environmental testing (vibration, shock, thermal vacuum), and performance validation
• Participate in design reviews (PDR, CDR) and interface directly with customers and program teams
• Collaborate cross-functionally with optical, manufacturing, quality, and systems engineering teams

Required Qualifications

• Bachelor’s or Master’s degree in Mechanical Engineering, Aerospace Engineering, or related field
• 5+ years of experience in opto‑mechanical design (space or aerospace preferred)
• Strong understanding of structural mechanics, thermal analysis, and precision mechanical design
• Experience designing for launch environments (random vibration, shock, static loads)
• Proficiency in 3D CAD software (SolidWorks, Creo, NX, or similar)
• Experience with FEA tools (ANSYS, NASTRAN, or equivalent)
• Familiarity with optical system fundamentals and alignment sensitivity
• Experience with GD&T and tolerance stack‑up analysis
• Knowledge of aerospace materials and space qualification standards

Preferred Qualifications

• Direct experience designing hardware for satellite telescopes or space imaging systems
• Experience with lightweight mirror mounts, flexures, kinematic designs, and athermalization strategies
• Familiarity with silicon carbide or other advanced space‑qualified optical materials
• Experience supporting thermal vacuum and vibration testing
• Understanding of stray light control and baffle design
• Active or ability to obtain a U.S. security clearance

Key Competencies

• Strong analytical and problem‑solving skills
• Attention to precision and detail in high-performance systems
• Ability to work in multidisciplinary engineering teams
• Effective written and verbal communication skills
• Self‑directed and capable of managing multiple program priorities

Why Join Us

You will play a critical role in developing next‑generation satellite imaging systems that demand extreme precision, stability, and reliability. This is an opportunity to work on mission‑critical hardware deployed in challenging space environments where engineering excellence directly impacts performance.

170 Pondview Dr., Meriden, CT 06450 USA