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Xona Space Systems is seeking a Spacecraft Test Engineer to own mechanical and environmental testing across the spacecraft development lifecycle for Pulsar, an advanced positioning satellite constellation in Low Earth Orbit. This role spans early R&D and design de-risking through first-article spacecraft qualification, sitting at the intersection of spacecraft design, mechanical engineering, materials science, environmental testing, and systems engineering.
You will develop and execute tests that identify failure modes early, establish engineering margins through physical data, and demonstrate spacecraft readiness for launch. Key responsibilities include:
**Early-Stage R&D and Design De-Risking:** Identify high-risk mechanical, structural, thermal, and material risks early in development. Design and execute coupon-, component-, and subassembly-level tests to characterize materials, interfaces, and processes before design freeze. Develop test-derived allowables and engineering data for critical mechanical interfaces. Partner with mechanical, structures, thermal, payload, electrical, and systems engineers to translate test results into actionable design changes.
**In-House Test Capability Development:** Build and expand Xona's internal capabilities for advanced mechanical and materials testing. Develop test methods for mechanical strength, tensile testing, optical properties, coefficient of thermal expansion (CTE), and thermal characterization. Design and build test fixtures, instrumentation, and data acquisition systems. Establish repeatable test methods, procedures, and calibration practices. Use physical testing to validate and improve analytical and simulation models.
**First-Article Spacecraft Vibration Testing:** Own planning and execution of first-article spacecraft vibration testing from test definition through final reporting. Develop vibration test plans and procedures in coordination with multiple engineering teams. Define test configurations, instrumentation, accelerometer placement, and fixture requirements. Design spacecraft vibration fixtures and ground support equipment. Coordinate with external vibration facilities. Monitor test data in real time, identify anomalies, and make engineering decisions during execution. Lead investigation and root-cause analysis of test anomalies.
**Thermal Vacuum & Environmental Testing:** Support spacecraft-level thermal vacuum (TVAC) test campaigns including planning, instrumentation, execution, and post-test analysis. Coordinate spacecraft configuration, GSE, chamber interfaces, and thermal instrumentation. Execute thermal cycling and TVAC testing while monitoring spacecraft performance. Work closely with thermal engineers to correlate thermal models against physical test data. Lead post-TVAC inspections, functional testing, and anomaly resolution.
**Spacecraft Qualification & Verification:** Develop spacecraft-level verification strategies connecting early R&D testing with formal qualification and acceptance testing. Define test objectives, success criteria, instrumentation, and data requirements. Support design reviews with test-derived evidence. Develop and maintain test plans, procedures, reports, and verification documentation. Lead test readiness reviews.
**Cross-Functional Engineering:** Serve as technical point of contact between spacecraft test and broader engineering organization. Work closely with mechanical, structures, thermal, electrical, payload, GNC, systems engineering, manufacturing, and operations teams. Provide early, test-driven feedback to designers. Mentor engineers and technicians in spacecraft test methods and hardware handling.
This is a highly hands-on role with significant technical ownership. You will shape how Xona tests its spacecraft and turn lessons learned into repeatable processes for a growing fleet.
**Requirements:**
- Bachelor's degree in Mechanical Engineering, Aerospace Engineering, or related field
- 3+ years of relevant engineering experience with demonstrated ownership of hardware testing and verification
- Experience developing and executing mechanical or environmental tests on complex hardware
- Direct experience with one or more spacecraft environmental tests (vibration, thermal vacuum, thermal cycling, shock, or structural testing)
- Strong understanding of mechanical engineering fundamentals including structural mechanics, materials, thermal effects, fasteners, joints, and interfaces
- Experience developing test fixtures, instrumentation, and data acquisition systems
- Ability to interpret test data, identify anomalies, and perform root-cause analysis
- Strong technical writing skills for test plans, procedures, and reports
- Ability to work hands-on with flight hardware and test equipment
- Strong communication skills and ability to work across multiple engineering disciplines
- Demonstrated ability to take ownership of ambiguous problems and drive them to completion
**Preferred Qualifications:**
- Direct experience leading spacecraft-level vibration or TVAC campaigns
- Experience with first-article or qualification testing of spacecraft or aerospace hardware
- Experience with materials characterization, allowables testing, or mechanical/materials test methods
- Experience correlating thermal or structural models with physical test data
- Experience designing test fixtures and GSE using CAD
- Familiarity with spacecraft environmental test standards and practices
- Experience with accelerometers, thermocouples/RTDs, strain gauges, load cells, or other test instrumentation
- Experience with data acquisition systems and test automation
- Familiarity with Python, MATLAB, LabVIEW, or similar tools for test automation and data analysis
- Experience working with external test facilities and vendors
- Experience with spacecraft integration, test, and launch operations
**Note:** U.S. citizenship or lawful permanent resident status required to comply with U.S. Government space technology export regulations.
