Hardware Engineer

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.

What is Aurelius Systems?

Aurelius Systems is a directed energy company developing edge-deployed laser systems for cUAS applications

We shoot down drones with laser guns

Why?

The US and our allies have prepared for a world where we will be fighting increasingly large and sophisticated systems (Planes, Aircraft carriers, etc), but this world never came. The future of warfare will involve large numbers of small-scale and mass-manufacturable drones, and we aren’t prepared to defend our country from these threats abroad or domestically. Aurelius Systems has set out to address this problem by equipping the US and our allies with the systems they need to fight current and future conflicts in a scalable and cost-effective manner.

Job Description

We are seeking an inventive Hardware Engineer to drive structural and thermal analysis and design for rapid prototyping of our laser defense systems. You will lead finite element analysis (FEA), thermal management, vibration and robustness testing, and prototype validation to deliver rugged, field ready hardware. This role spans concept through production, emphasizing a strong bias toward hands on testing and iterative mechanical prototyping in demanding defense environments.

Key Responsibilities

Thermal Management: Develop and validate thermal solutions (passive and active) for high power laser modules; conduct conjugate heat transfer and transient thermal simulations.

FEA & Structural Simulation: Perform stress, vibration, and modal analyses using ANSYS, SolidWorks Simulation, or equivalent tools; interpret results to 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) with an extreme bias toward testing; plan and execute vibration, shock, environmental, and robustness tests to validate hardware under field conditions.

Design for Manufacturability (DFM): Conduct DFM reviews to optimize geometry, tolerances, and material selection for efficient production; collaborate with suppliers and fabricators to ensure manufacturable designs.

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, maintaining quality and compliance with MIL STD and ITAR requirements.

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).

Technical Skills:

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

Education: BS/MS in Mechanical Engineering, Aerospace Engineering, or similar field.

Soft Skills: Extreme bias for action, strong problem solving, communication, and project management abilities.

Nice to Haves

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

Send all applications w/ resume, evidence of excellent previous work, portfolio, github/website and a description of the most impressive thing you've done to