Mechanisms Engineer

Role Overview

Zachary Piper Solutions is seeking a hands-on Mechanisms Engineer to design, build, and scale deployable spacecraft hardware—from hinges and release mechanisms to actuators and gimballed assemblies—for high‑reliability phased-array satellite systems. You will work from concept to flight: CAD, analysis, prototyping, troubleshooting, and scaling to high-volume satellite production.

This is a highly cross‑functional role with direct impact on launch cadence, constellation growth, and mission reliability.

Key Responsibilities

• Design, model, and analyze deployable mechanical hardware (hinges, releases, gimbals, actuators) using CATIA, SolidWorks, and NASTRAN.
• Ensure full mechanical tolerance and quality control through GD&T, ESD safety practices, and cleanroom assembly standards.
• Perform detailed FEA, mechanism modeling, and materials validation for mission‑critical moving hardware.
• Rapidly prototype components using carbon fiber composites, machined metals, additive manufacturing, and advanced layups.
• Lead hardware test campaigns: vibration, thermal, TVAC, shock, and deployment reliability.
• Conduct formal root-cause investigations using 8D, Fishbone/Ishikawa, and iterative troubleshooting to resolve flight and test failures.
• Transition hardware from one‑off prototypes to high‑rate production (target: 6 satellites/month).
• Own manufacturing documentation, including detailed drawings, BOMs, assembly procedures, and release packages.
• Coordinate closely with machine shops, composite vendors, and precision mechanism suppliers.
• Support integration operations including periodic travel to Cape Canaveral, vendor sites, and partner facilities.
• Work alongside structures, mechanisms, systems engineering, quality, and assurance teams on subsystem integration.
• Mentor junior engineers; drive continuous improvement for hardware reliability, manufacturability, and deployment performance.
• Influence strategic hardware decisions for constellation expansion and long‑term platform scaling.

Required Qualifications

• Bachelor’s or Master’s in Mechanical Engineering, Aerospace Engineering, or related field.
• Demonstrated experience with deployable spacecraft mechanisms or high‑precision mechanical systems.
• Strong proficiency with CATIA or SolidWorks, plus FEA tools such as NASTRAN, ANSYS, Abaqus, etc.
• Hands-on test experience: vibration, thermal, TVAC, shock, or mechanism deployments.
• Knowledge of GD&T, ASME Y14.5, ESD/cleanroom best practices, and precision assembly.
• Experience with root-cause methods (8D, RCA, FTA) and hardware validation.

Preferred Qualifications

• Background in spacecraft, aerospace mechanisms, robotics, or high‑reliability electromechanical devices.
• Experience with carbon fiber layups, composites design, or high-stiffness lightweight structures.
• Exposure to high‑volume manufacturing or NewSpace production environments.
• Ability to thrive in a fast‑moving, ambiguity‑heavy engineering culture.

Compensation & Benefits

• Base Salary: $90,000, commensurate with experience and technical depth.
• Competitive benefits package including health, dental, vision, and retirement options.
• Opportunities for relocation support

Keywords: #LI-CG1 #ONSITE

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