Position Summary

The Design Engineer II is responsible for the design, development, and implementation of solutions that support the manufacturing, testing, handling, transportation, and delivery of aerospace hardware. This role focuses on the design of Ground Support Equipment (GSE), manufacturing kitting systems, assembly fixtures, shipping containers, and protective packaging solutions that ensure sensitive flight and non-flight hardware remains protected throughout its lifecycle.

The successful candidate will possess strong mechanical design skills, proficiency in SolidWorks or equivalent CAD software, and a thorough understanding of designing for the protection, handling, transportation, and storage of high-value aerospace components and assemblies.

This position works closely with Manufacturing Engineering, Production, Supply Chain, Quality, Test Engineering, and Program Management to develop innovative solutions that improve efficiency, reduce risk, and protect mission-critical hardware.

Essential Duties and Responsibilities

Ground Support Equipment (GSE) Design

Design and develop aerospace Ground Support Equipment used for assembly, integration, testing, transportation, storage, and installation of flight hardware and support systems.
Create detailed 3D models, fabrication drawings, assembly drawings, and bills of materials (BOMs).
Design equipment that meets safety, ergonomic, structural, and operational requirements.
Support design reviews, prototype evaluations, and implementation of new GSE into production and test operations.
Improve existing support equipment to increase reliability, efficiency, and maintainability.

Manufacturing Support & Kitting Systems

Design kitting boxes, component storage systems, assembly fixtures, workstations, carts, and material handling solutions.
Develop solutions that support lean manufacturing practices and improve production efficiency.
Create protective handling fixtures that minimize the risk of damage to sensitive aerospace hardware during assembly and movement.
Collaborate with technicians and manufacturing personnel to optimize product flow and assembly operations.

Aerospace Packaging & Transportation Design

Design packaging systems, reusable shipping containers, transport fixtures, foam inserts, protective cases, and custom crating solutions.
Develop packaging that protects hardware from vibration, shock, electrostatic discharge (ESD), contamination, moisture, and environmental exposure.
Ensure packaging solutions support domestic and international transportation requirements.
Conduct engineering assessments to validate structural integrity and protection levels during handling and shipment.
Support packaging testing, transportation simulations, and failure investigations as required.

Engineering Documentation

Generate and maintain engineering drawings, specifications, and design documentation.
Create and manage engineering change notices (ECNs) and revision-controlled design packages.
Develop manufacturing instructions and assembly documentation to support production.
Maintain compliance with company engineering standards and configuration management processes.

Cross-Functional Collaboration

Work directly with Production, Quality, Supply Chain, Integration & Test, and Program teams to define requirements and develop solutions.
Support root cause investigations involving damaged hardware, handling incidents, packaging failures, and transportation-related issues.
Participate in design reviews and risk assessments for new products and programs.
Provide technical support during fabrication, assembly, integration, and shipment activities.

Required Qualifications

Education

Bachelor's degree in Mechanical Engineering, Aerospace Engineering, Manufacturing Engineering, or a related engineering discipline.

Experience

3-7 years of experience in mechanical design, aerospace tooling, fixtures, packaging design, manufacturing engineering, or related engineering disciplines.
Experience designing fabricated assemblies, support equipment, tooling, fixtures, or transportation systems.
Experience supporting manufacturing or aerospace production environments preferred.

Technical Skills

Proficiency with SolidWorks required; experience with Creo, NX, CATIA, Inventor, or similar CAD platforms may be considered.
Strong understanding of mechanical design principles and engineering drawing creation.
Experience designing weldments, sheet metal assemblies, machined components, and structural frameworks.
Ability to create detailed drawings with GD&T in accordance with ASME standards.
Understanding of aerospace hardware handling, transportation, and protection requirements.
Knowledge of material selection, fabrication methods, and manufacturing processes.
Ability to perform engineering calculations related to structural integrity, load capacity, vibration, and shock protection.
Familiarity with Microsoft Office and Product Lifecycle Management (PLM) systems.

Desired Qualifications

Aerospace, defense, space systems, satellite, launch vehicle, propulsion, or aviation industry experience.
Experience designing support equipment for flight hardware, propulsion systems, or test operations.
Working knowledge of packaging standards for aerospace and high-value hardware.
Familiarity with vibration, shock, and transportation testing methods.
Experience with finite element analysis (FEA) and structural analysis tools.
Knowledge of ESD, contamination control, and clean-room handling requirements.
Lean manufacturing or Six Sigma experience.

Key Competencies

Strong mechanical design and problem-solving capabilities.
Ability to design practical solutions that protect sensitive aerospace hardware.
Excellent CAD modeling and technical documentation skills.
Strong organizational and project management abilities.
Effective communicator capable of working across engineering and manufacturing teams.
Hands-on approach with the ability to work in both office and manufacturing environments.
High attention to detail and commitment to quality and mission success.

Physical Requirements

Ability to support manufacturing, integration, and test operations in production environments.
Ability to inspect hardware, packaging systems, support equipment, and assembly operations.
Occasional lifting of materials and equipment up to 25 pounds.
Occasional travel to suppliers, customers, test facilities, or launch sites as required.

Success Measures

A successful Design Engineer II will:

Deliver robust Ground Support Equipment that improves safety and operational efficiency.
Design packaging and transportation systems that prevent damage to high-value aerospace hardware.
Improve manufacturing productivity through effective kitting and material handling solutions.
Produce high-quality engineering documentation with minimal revisions.
Support successful hardware delivery, integration, testing, and customer acceptance with zero preventable handling or shipping damage.
Contribute to continuous improvement initiatives that reduce cost, risk, and cycle time across aerospace programs.

Export Control / Compliance Requirements

To conform to U.S. Government space technology export regulations, including the International Traffic in Arms Regulations (ITAR), you must be a U.S. citizen, lawful permanent resident of the U.S., protected individual as defined by 8 U.S.C. 1324b(a)(3), or eligible to obtain the required authorizations from the U.S. Department of State.

Compensation & Benefits

Competitive salary range: $105,000-$125,000 (dependent on experience and qualifications)

ExoTerra offers a comprehensive total compensation package, including competitive salary, a discretionary annual bonus plan, paid time off (PTO), a comprehensive health benefits package, and various other benefits. When you join our team, you're not just an employee; you become part of a dynamic community dedicated to innovation and excellence.

Equal Employment Opportunity Statement

ExoTerra is an Equal Opportunity Employer. Employment decisions are made without regard to race, color, religion, national or ethnic origin, sex, sexual orientation, gender identity or expression, age, disability, protected veteran status, or other characteristics protected by law.