Hardware Engineer Job at Aurelius Systems in San Francisco

Citizens and permanent residents only - we do not sponsor and cannot hire non-citizens or PRs. We work 6 days a week in the office in downtown San Francisco, no remote available. Overview Aurelius Systems is a directed energy company developing edge-deployed laser systems for cUAS applications. We shoot down drones with laser guns. The role focuses on hardware engineering for rapid prototyping of laser defense systems, leading structural and thermal analysis, and hands-on prototype testing in demanding defense environments. Responsibilities Thermal Management: Develop and validate thermal solutions (passive and active) for high‑power laser modules; conduct conjugate heat transfer and transient thermal simulations and FEA Structural Simulation: Perform stress, vibration, and modal analyses using ANSYS, SolidWorks Simulation, or equivalent tools; optimize designs for durability, weight, and dynamic loads Mechanical Design & Analysis: Create and refine CAD models for thermal management and structural prototypes Prototype Development & Testing: Drive hands‑on mechanical prototyping (CNC, additive, or other rapid fabrication); plan and execute vibration, shock, environmental, and robustness tests Design for Manufacturability (DFM): Conduct DFM reviews to optimize geometry, tolerances, and material selection; collaborate with suppliers and fabricators Material Selection & Qualification: Evaluate metals, polymers, and composites for mechanical strength, thermal conductivity, and EMI compatibility; develop and execute mechanical and environmental test protocols Manufacturing Readiness: Generate BOMs, GD&T drawings, and assembly instructions; oversee transition of prototypes to production with MIL‑STD and ITAR considerations Cross‑Functional Collaboration: Partner with optics, electronics, firmware, and controls teams to integrate hardware modules; provide hands‑on support during system assembly, integration, and field testing Qualifications Hyper Engineer – your brain only releases dopamine when you're building Experience: 2-8 years in mechanical or hardware engineering roles (defense, aerospace, or related fields) Proficient in CAD (SolidWorks, Creo, or similar) Strong background in FEA (ANSYS, SolidWorks Simulation) Thermal analysis expertise (CFD and heat transfer software) Hands‑on mechanical prototyping and test fixture development Experience planning and executing vibration, shock, and environmental testing Knowledge of materials science, stress analysis, and manufacturing methods BS/MS in Mechanical Engineering, Aerospace Engineering, or similar field Soft Skills Extreme bias for action, strong problem‑solving, communication, and project‑management abilities Vacuum or environmental chamber testing experience Familiarity with laser safety standards and optical alignment fixtures Background in EMI/EMC design and shielding Security clearance or ITAR compliance experience Seniority level Mid-Senior level Employment type Full-time Job function Engineering and Information Technology Industries: Defense and Space Manufacturing #J-18808-Ljbffr