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Aurelius Systems is a VC-backed defense tech startup building autonomous, edge-deployed directed energy systems (laser weapons) for counter-UAS applications. The company operates from a San Francisco lab and a Detroit manufacturing hub, with weekly field testing on a private 400-acre range.
In this Senior Mechanical Engineer role, you will own major mechanical subsystems end-to-end on the Archimedes platform, ensuring they survive demanding field conditions. Your responsibilities include:
- Mechanical design of major subsystems: laser source and head enclosures, gimbal and beam director structure, mounts
- Ruggedization against MIL-STD shock, vibration, humidity, dust, and austere environments
- Thermal management for high-power laser and electronics packaging
- Precision optomechanical packaging that maintains alignment through shock and thermal cycles
- FEA analysis (static, modal, random vibration, shock response spectrum) with correlation to test data
- Building and running test rigs and instrumentation for bench validation
- Design for manufacturability (DFM) and handoff coordination with the Detroit manufacturing hub
- Design reviews and mentorship of junior mechanical engineers
You will work hands-on from architecture through bench validation, field correlation, and production handoff, collaborating closely with Staff and Principal engineers across mechanical, electrical, optical, and software disciplines.
The company culture emphasizes extreme bias for action, rapid iteration, and self-direction. Core hours are Monday–Friday, 9 AM–6 PM, with sprint periods (nights/weekends) before demos or field tests, followed by ramp-down periods. Weekly field testing means your work has immediate, tangible impact.
Benefits include competitive salary and equity, UnitedHealthcare medical/dental/vision, 18 days PTO plus 5 sick days, travel to field test events, daily lunches and office snacks, and an e-bike/scooter stipend up to $500.
REQUIREMENTS:
- 5+ years in mechanical engineering on ruggedized, field-deployable, or high-performance systems
- At least one subsystem taken from prototype to production
- Strong FEA expertise (ANSYS, Nastran, Abaqus, or equivalent) backed by hands-on bench work
- Hands-on design experience with MIL-STD-810 or equivalent shock and vibration standards
- Thermal design for high-power systems
- Demonstrated ability to learn fast and become effective in new domains within months
- BS or MS in Mechanical Engineering, Aerospace, or related field (what you've built matters more than credentials)
IDEAL BACKGROUND: Defense hardware, airborne or ground vehicle systems, F1 and high-performance automotive, aerospace, maritime, ruggedized electronics, or directed energy and field-deployed sensor programs. Domain matters less than shipping hardware that had to survive.
NICE-TO-HAVES:
- Laser, directed energy, or high-power hardware experience
- Optical bench or precision instrument ruggedization
- MIL-STD-461 EMI/EMC awareness for mechanical integration
- Vehicle-mounted systems
- Manufacturing ramp experience
NOT A FIT IF: You've only done commercial or consumer product design, your work is simulation-only without bench validation, or you've spent years on one narrow subcomponent without seeing the system around it.
NOTE: This role requires access to export-controlled information and U.S. Person status as defined by U.S. law (U.S. citizens, legal permanent residents, or certain protected classes of asylees and refugees).
