Sr. Structural Engineer

Magma Space Inc.; Washington, Northern (District of Columbia, KY); Hybrid; USD 120,000 - 190,000; Full time

Benefits offered by this job

Health, dental, vision

401(k) matching

On-site gym

Flexible schedule

Remote/hybrid options

Relocation assistance

Job summary

Magma Space Inc. in Washington, DC is seeking a Senior Mechanical Engineer to lead end-to-end mechanical development for satellite subsystems. You will design, test, and implement space mechanisms such as reaction wheels and control moment gyroscopes, collaborating with GNC, electrical, and software teams.

The role emphasizes hands-on testing, thermal-vacuum environments, and production readiness, with opportunities to mentor junior staff and shape future satellite missions.

Qualifications

• Bachelor's or Master's degree in Mechanical, Aerospace, or related field.
• 5+ years hands-on hardware design, integration, and test — preferably space hardware.
• Proficiency in 3D CAD (SolidWorks, Creo, or NX) and GD&T for detailed drawings.
• Experience with FEA or physics modeling (Nastran/Patran, ANSYS, COMSOL, or equivalent).
• Hands-on lab experience: mechanical assembly, vibration testing, thermal-vacuum cycling, and precision metrology.
• Familiarity with materials selection for space (aluminum alloys, composites, bearing materials, lubrication) and cleanroom protocols.
• Excellent problem-solving and collaboration across multidisciplinary teams.
• Scripting experience (Python, MATLAB, or similar) is a plus.
• U.S. citizen or permanent resident required (DoW and EAR/ITAR project eligibility).

Responsibilities

• Lead full-lifecycle mechanical development — concept generation, detailed design, prototyping, testing, and production — across reaction wheels, control moment gyroscopes, and other space mechanisms.
• Design systems and components that meet program requirements, including current efforts at AFRL, on the ISS, and on commercial and Defense missions such as RPOD.
• Generate new concepts to advance our mechanical design capabilities.
• Perform preliminary structural and thermal analyses (FEA via Nastran, ANSYS, or SolidWorks Simulation) to validate performance margins in space environments.
• Build and execute test plans in lab and HIL/SIL environments; analyze data, identify failure modes, and iterate designs to meet mission requirements.
• Define and manage Bills of Materials (BOMs); specify components with vendors, evaluate bids, and oversee procurement.
• Inspect and qualify delivered hardware; coordinate non-conformance resolutions with suppliers.
• Develop assembly, integration, and test (AIT) procedures; supervise integration in cleanroom and vibration/thermal-vacuum environments.
• Identify, formulate, and produce effective solutions to emerging design and integration problems.
• Collaborate closely with GNC, electrical, and software teams to ensure seamless hardware-software integration.
• Document design decisions, test reports, and interface control documents (ICDs) for both internal review and customer deliverables.
• Mentor junior engineers and champion best practices in space mechanisms.

Skills

Mechanical design

3D CAD

FEM/FEA

Test & integration

Cross-disciplinary collaboration

Python/MATLAB scripting

Education

Bachelor's or Master's in Mechanical/Aerospace

Tools

SolidWorks

Creo

NX

Nastran/Patran/ANSYS/COMSOL

Job description

We are seeking a passionate and experienced Senior Mechanical Engineer to join our team in Washington, DC. The ideal candidate will have a strong background in mechanical design, from concept through analysis, prototyping, and production. This role requires a hands-on approach, the ability to test electromechanical assemblies for our satellite subsystems, and a strong team-oriented mindset.

About Magma Space

Magma Space is on a mission to deliver the most precise spacecraft pointing ever achieved, for demanding applications like directed energy, optical communication, in-space precision manufacturing and more. Leveraging proprietary magnetically levitated actuators that reduce vibrations 20X, over 50 new high-precision sensors per satellite, and AI/ML-infused control software, our capabilities drastically enhance pointing accuracy while enabling autonomy and holistic performance improvements. Magma Space is developing a suite of products that benefit from each other, bringing an ecosystem of smart technologies and information to meet the future's most demanding mission objectives.

Description

About Us

At Magma Space, we're on a mission to deliver the most precise spacecraft pointing ever achieved. We are developing groundbreaking control actuators, including magnetically levitated reaction wheels and control moment gyroscopes that drastically reduce onboard vibrations while delivering unmatched momentum. But our vision goes beyond hardware - we're at the forefront of integrating AI-enhanced software for real-time environment monitoring with novel sensing capabilities. Our goal is to provide satellites with an unprecedented level of stability, agility, and accuracy, enhancing satellite capabilities like never before.

We're proud to be supported by NASA and the U.S. Space Force, and we're now partnering with the Department of Defense on a RPOD (Rendezvous, Proximity Operations, and Docking) project. Across our efforts, you'll oversee mechanical design and development. Your first project will be in advancing our upcoming test programs, including ground-based testing at the AFRL and orbital testing on the ISS, commercial, and Defense missions.

Join us at Magma Space and make a lasting impact on the next generation of space missions!

Key Responsibilities

• Lead full-lifecycle mechanical development — concept generation, detailed design, prototyping, testing, and production — across reaction wheels, control moment gyroscopes, and other space mechanisms.
• Design systems and components that meet program requirements, including current efforts at AFRL, on the ISS, and on commercial and Defense missions such as RPOD.
• Generate new concepts to advance our mechanical design capabilities.
• Perform preliminary structural and thermal analyses (FEA via Nastran, ANSYS, or SolidWorks Simulation) to validate performance margins in space environments.
• Build and execute test plans in lab and HIL/SIL environments; analyze data, identify failure modes, and iterate designs to meet mission requirements.
• Define and manage Bills of Materials (BOMs); specify components with vendors, evaluate bids, and oversee procurement.
• Inspect and qualify delivered hardware; coordinate non-conformance resolutions with suppliers.
• Develop assembly, integration, and test (AIT) procedures; supervise integration in cleanroom and vibration/thermal-vacuum environments.
• Identify, formulate, and produce effective solutions to emerging design and integration problems.
• Collaborate closely with GNC, electrical, and software teams to ensure seamless hardware-software integration.
• Document design decisions, test reports, and interface control documents (ICDs) for both internal review and customer deliverables.
• Mentor junior engineers and champion best practices in space mechanisms.

Qualifications

• Bachelor's or Master's degree in Mechanical, Aerospace, or a related engineering discipline.
• 5+ years of hands-on experience in hardware design, integration, and test — preferably with space hardware such as reaction wheels, gyros, or other flight mechanisms.
• Proficiency in 3D CAD (SolidWorks, Creo, or NX) and familiarity with GD&T for detailed part and assembly drawings.
• Experience with FEA or physics modeling (Nastran/Patran, ANSYS, COMSOL, or equivalent) and thermal analysis techniques is desirable.
• Hands-on lab experience: mechanical assembly, vibration testing, thermal-vacuum cycling, and precision metrology.
• Familiarity with materials selection for space (aluminum alloys, composites, bearing materials, lubrication) and cleanroom protocols.
• Excellent problem-solving and critical-thinking skills, with a track record of bringing complex hardware from concept to flight readiness.
• Demonstrated ability to collaborate across multidisciplinary teams and communicate effectively with both technical and non-technical stakeholders.
• Strong organizational skills, attention to detail, and the ability to manage multiple priorities in a fast-paced environment.
• Scripting experience (Python, MATLAB, or similar) is a plus.
• U.S. citizen or permanent resident required (DoW and EAR/ITAR project eligibility).

What We Offer

• The opportunity to work on cutting-edge space mechanisms with real DoW applications.
• A highly collaborative, innovative, and rapidly growing team environment.
• Competitive compensation package, including salary and equity.
• Comprehensive benefits: health, dental, vision, 401(k) matching, paid vacation, sick leave, parental leave, and holidays.
• On-site gym access and wellness programs.
• Flexible work schedule and remote/hybrid options.
• Relocation assistance for qualified candidates.
• The chance to shape the future of satellite autonomy and national security.

The selected applicant will be required to pass a pre-employment third-party background check and reference check.

Magma Space Inc. is an equal opportunity employer. We celebrate diversity and are committed to creating an inclusive environment for all employees. Even if you don't meet all the qualifications as outlined here, but are still excited about the role, we encourage you to apply anyway.