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About the Role
We are seeking a Senior Mechanical Engineer to own major mechanical subsystems for our directed energy systems, ensuring their ruggedization against environmental extremes and managing structural, thermal, and packaging aspects. You will work hands-on from architecture through validation and production handoff.
Responsibilities
- Mechanical design of major subsystems including laser source and head enclosures, gimbal and beam director structure, and mounts.
- Ensure survivability to MIL-STD shock, vibration, humidity, dust, and austere environments.
- Manage thermal management for high-power laser and electronics packaging.
- Develop precision and optomechanical packaging that maintains alignment through shock and thermal cycles.
- Perform FEA (static, modal, random vibration, shock response spectrum) and correlate to test results.
- Build and operate test rigs, instrumentation, and perform bench validation.
- Oversee DFM and the handoff to manufacturing.
- Conduct design reviews and mentor junior ME team members.
Requirements
- 5+ years in mechanical engineering on ruggedized, field-deployable, or high-performance systems.
- Experience taking at least one subsystem from prototype to production.
- Strong FEA skills (ANSYS, Nastran, Abaqus, or equivalent) with supporting bench work.
- Hands-on design experience meeting MIL-STD-810 or equivalent shock and vibration standards.
- Experience with thermal design for high-power systems.
- Demonstrated ability to learn new domains quickly.
- Experience in defense hardware, airborne or ground vehicle systems, F1 and high-performance automotive, aerospace, maritime, ruggedized electronics, or directed energy and field-deployed sensor programs.
- Experience owning a system that survived shock, vibration, and environmental extremes in a tight, deployable package, including modeling, building, instrumenting, and correlating it.
Skills
- Mechanical Design
- Ruggedization
- Thermal Management
- Optomechanical Packaging
- FEA (ANSYS, Nastran, Abaqus)
- Test Rig Development
- DFM
- Design Reviews
- Laser Systems
- Directed Energy
- High-Power Hardware
- Optical Bench Ruggedization
- Precision Instrument Ruggedization
- MIL-STD-461 EMI/EMC
- Vehicle-mounted Systems
- Manufacturing Ramp
- First Principles Debugging
- Clear Communication
Location
- San Francisco
- Detroit
Work Type
- Full-time
- Onsite
Experience Level
- Senior
Education Level
- BS or MS in Mechanical, Aerospace, or related field
Salary/Compensations
- Competitive salary and equity
Benefits
- United Health Care medical, dental, and vision coverage
- 18 days PTO plus 5 sick days
- Travel to field test events and range days
- Covered daily lunches and office snacks and drinks
- E-bike and scooter stipend up to $500
- Direct access to leadership
- 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 are a small team of engineers, former US military, and subject matter experts scaling America's directed energy dominance.
- We aim to be the first cost-effective, reliable, and robust laser weapon system.
- Our operations are characterized by a small team, unreasonable output, and a focus on doing the work at hand.
- We have a San Francisco lab and a Detroit manufacturing hub, with weekly field tests on our own 400-acre private range.
Equal Opportunity
- This role requires access to export-controlled information or items that require U.S. Person status. As defined by U.S. law, individuals who are any one of the following are considered to be a U.S. Person: (1) U.S. citizens, (2) legal permanent residents (a.k.a. green card holders), and (3) certain protected classes of asylees and refugees, as defined in 8 U.S.C. 1324b(a)(3).