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About the Role

You'll own the beam train end-to-end, from simulation to field demo. You take Zemax models and turn them into hardware that works downrange. You run aberration analysis on long path, large aperture, broad frequency systems. You spec the optics, design the opto-mechanical assemblies, build ruggedized hardware, and align and characterize integrated systems on the bench and in the field. This is a senior role where you will advise on optical strategies.

Responsibilities

Lead beam train optical design end-to-end
Own aberration mitigation on long path, large aperture, broad frequency systems
Spec and qualify optical components for high power laser operation
Design ruggedized opto-mechanical mounts, housings, and assemblies for field-deployed environments
Run opto-mechanical tolerance analysis and validate designs through structural and thermal modeling
Lead optical alignment, characterization, and beam quality measurement on integrated systems
Support field testing end-to-end: setup, alignment, data collection, post-test analysis, failure writeups
Work directly with fabricators and vendors on DFM, tolerancing, and production readiness
Generate optical system documentation, drawings, and BOMs meeting MIL-STD and ITAR requirements

Requirements

5+ years (or PhD + 3 years) in opto mechanical design with shipped hardware
Optical system design in Zemax OpticStudio
Aberration mitigation experience on long path, large aperture, broad frequency systems
Industrial laser tooling background
Hands-on optical alignment and characterization experience
Mechanical design experience in CAD (SolidWorks preferred) for opto-mechanical mounts, housings, and assemblies
Understanding of thermal and structural effects on optical performance
Familiarity with high-power laser optics and their damage thresholds, coating selection, thermal lensing
Comfortable working across mechanical, electrical, and laser teams to integrate optical subsystems
Must have shipped hardware, not just theoretical or software-based experience
Must have designed a beam train, taken it from simulation to a working system, and performed alignment
This role requires access to export-controlled information or items that require "U.S. Person" status (U.S. citizen, legal permanent resident, or certain protected classes of asylees and refugees).

Skills

Zemax OpticStudio
SolidWorks
Opto-mechanical design
Optical alignment
Optical characterization
Beam quality measurement
Aberration mitigation
High-power laser optics
Coating selection
Thermal lensing
Structural modeling
Thermal modeling
DFM
Tolerancing
Production readiness
MIL-STD
ITAR

Location

San Francisco
Detroit

Work Type

Onsite
Full-time

Experience Level

Senior

Education Level

BS or MS in Optical Engineering, Physics, Mechanical Engineering, or related field

Benefits

Competitive salary + equity
United Health Care medical, dental, and vision coverage
Flexible 18 days PTO + 5 sick days
Travel to field test events and range days
Covered daily lunches and office snacks + drinks
E-bike / scooter stipend (Up to $500)
Direct access to leadership and real ownership over your work

About the Company

Aurelius Systems is a VC backed defense tech startup building autonomous, edge deployed directed energy systems for counter-UAS.
We build laser weapons to shoot down drones.
We're a small team of engineers, former US military operators, and subject matter experts scaling America's directed energy dominance.
We aim to be the first cost effective, reliable and robust laser weapon system.
We operate with a small team, unreasonable output, and focus on doing the work.
We have a San Francisco lab, a Detroit manufacturing hub, and field test weekly on our own 400-acre private range.