Senior Flight-Hardware Assembly & Design Technician

Allocor Tech; Crozet (VA); On-site; USD 70,000 - 110,000; Full time

Benefits offered by this job

Equity opportunities

Cash bonus

Top-tier medical benefits

HSA funded plan

401(k) with company match

Unlimited PTO

Job summary

Allocor.tech in Virginia seeks a Senior Engineering Technician to bridge hands-on manufacturing with mechanical design and product architecture. You will own final assembly, harnessing, HIL test racks, and support PCB rework, collaborating with engineering to scale flight hardware for R&D and production.

You will apply DFM/DFM, maintain the digital twin in PLM, and lead tooling from early builds to production, ensuring safety, regulatory compliance and high first-pass quality.

Qualifications

• Able to inspect PCBs to IPC-A-610 Class 2 or better and perform installation and rework of thru-hole and fine-pitch SMT components to IPC Class 2 in a lead-free process.
• Extensive experience with PCBs and mechanical assemblies with ability to interpret schematics, drawings, and technical data packages.
• Proficiency with SolidWorks (parts, assemblies, drawings, BOMs) or equivalent 3D CAD; produce production-ready documentation.
• Experience applying DFM/DFA principles and supporting design reviews.
• Familiarity with product lifecycle management (PLM/MRP), ECO processes, and configuration control.

Responsibilities

• Own final electrical and mechanical assembly of products: soldering connectors and large components, rework of fuse and jumper resistor components, applying staking compound, and fastening assemblies together.
• Fabricate test and demonstration harnessing and support the engineering team with PCB rework and experimentation.
• Assemble hardware-in-the-loop (HIL) test racks and support integration and quality testing of subassemblies.
• Design and architect assemblies for new product development and continuous improvement of existing products; produce and maintain system architecture diagrams throughout the design cycle.
• Build SolidWorks assemblies, vendor drawings, BOMs, and prototypes. Design sheet metal and machined enclosures, ventilation systems, and structural mounts.
• Specify mechanical, electromechanical, optical, fluidic, and pneumatic components. Conduct DFA and DFM reviews on new designs.
• Calculate heat loads and size airflow, cold plates, TECs, and chillers. Perform linear static structural simulation. Verify thermal performance using thermocouples and IR thermography.
• Maintain the product digital twin in MRP/PLM systems; release new products; draft and execute ECOs.
• Serve as technical contact for machine shops and sheet metal fabricators. Issue data packages and perform first article inspection (FAI).
• Author and maintain assembly documentation and renderings. Support integration and QC. Travel for tool installations, field service, and refits as required.
• Conduct standards and compliance reviews and drive design changes per CE, EMC, NFPA, IEC, ISO, SEMI, ASME.

Skills

Hands-on mechanical aptitude

Interpret schematics and drawings

Documentation discipline

Tools

SolidWorks

3D CAD

PLM/MRP familiarity

Job description

Allocor.tech in Virginia seeks a Senior Engineering Technician to bridge hands-on manufacturing with mechanical design and product architecture. You will own final assembly, harnessing, HIL test racks, and support PCB rework, collaborating with engineering to scale flight hardware for R&D and production.

You will apply DFM/DFM, maintain the digital twin in PLM, and lead tooling from early builds to production, ensuring safety, regulatory compliance and high first-pass quality.