Aurelius Systems
Aerospace & DefenseDirect Ashby career site

Sr. Mechanical Engineer

Location
San Francisco, CA · On-site
Job type
Full-time
Level
Senior
Experience
5+ years
Education
Bachelor's degree
Listed
23 days ago

Skills & highlights for this role

  • FEA (ANSYS, Nastran, Abaqus)
  • MIL-STD-810
  • thermal design for high-power systems

Also useful

  • MIL-STD-461
  • optical bench ruggedization
  • laser systems

Stated benefits & perks

  • Health
  • Dental
  • Vision
  • Pto

The Role and Your Impact

We need a Senior Mechanical Engineer who owns major mechanical subsystems on Archimedes end to end and makes them survive the field. That means ruggedization of a fiber laser system against shock, vibration, moisture and environmental extremes, plus the structure, thermal management and precision packaging around the laser head and beam director. You'll work hands on from architecture through bench validation, field correlation and the production handoff to our Detroit manufacturing hub, alongside our Staff and Principal engineers.

What You'll Own

  • Mechanical design of major subsystems: laser source and head enclosures, gimbal and beam director structure, mounts
  • Survivability to MIL-STD shock, vibration, humidity, dust and austere environments
  • Thermal management for high-power laser and electronics packaging
  • Precision and optomechanical packaging that holds alignment through shock and thermal cycles
  • FEA (static, modal, random vibration, shock response spectrum) and correlation to test
  • Test rigs, instrumentation and bench validation you build and run yourself
  • DFM and the handoff to manufacturing in Detroit
  • Design reviews and raising the bar for the junior ME team

What We're Looking For

  • 5+ years in mechanical engineering on ruggedized, field-deployable or high-performance systems
  • At least one subsystem you took from prototype to production
  • Strong FEA (ANSYS, Nastran, Abaqus or equivalent) and the bench work to back it up
  • Hands-on design to MIL-STD-810 or equivalent shock and vibration standards
  • Thermal design for high-power systems
  • Evidence you learn fast. You got effective in a new domain in months, not years

Additional information

Where you probably come from: 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.

We want to talk if: You've owned a system that had to survive shock, vibration and environmental extremes in a tight, deployable package, and you modeled it, built it, instrumented it and correlated it.

Not a fit if: You've only done commercial or consumer product design, your work is simulation-only with no bench validation, or you've spent years on one narrow subcomponent without seeing the system around it.

Nice to Haves

  • Laser, directed energy or high-power hardware
  • Optical bench or precision instrument ruggedization
  • MIL-STD-461 EMI/EMC awareness for mechanical integration
  • Vehicle-mounted systems
  • Manufacturing ramp experience

Additional information

Education: BS or MS in Mechanical, Aerospace or related field. What you've built matters more than where you went to school.

How You Operate

  • Extreme bias for action. You'd rather build a prototype tomorrow than model it for a month
  • You characterize your own systems before the field does
  • Comfortable with ambiguity and fast iteration in a startup environment
  • You debug from first principles, not intuition alone
  • Clear communicator across mechanical, electrical, optical, and software teams
  • Self directed. You identify what needs to happen next and do it without being told

How We Work

Core hours are Monday through Friday, 9 to 6. When we're sprinting toward a demo or field test, the team ramps up - nights, weekends, whatever it takes to ship. When the sprint lands, we ramp down. We don't manufacture intensity for show.

Benefits

  • Competitive salary and equity
  • United Health Care medical, dental, and vision coverage
  • Flexible 18 days PTO plus 5 sick days
  • Travel to field test events and range days
  • Covered daily lunches and office snacks and drinks
  • E-bike and scooter stipend up to $500
  • Direct access to leadership and real ownership over your work

Export Control Notice

This role requires access to export-controlled information or items that require U.S. Person status. 1324b(a)(3).

Who We Are

Aurelius Systems is a VC backed defense tech startup building autonomous, edge deployed directed energy systems for counter-UAS. We build laser weapons to shoot down drones.

We're a small team of engineers, former US military, and subject matter experts scaling America's directed energy dominance. The first cost effective, reliable and robust laser weapon system.

Our namesake isn't an accident. Marcus Aurelius wrote about doing the work in front of you, every day, without excuses. Henry Ford didn't wait for permission to reinvent manufacturing. That's how we operate small team, unreasonable output, no hiding behind the unachievable.

In addition to our San Francisco lab, we opened our Detroit manufacturing hub and field test weekly on our own 400-acre private range.

Why Join Aurelius Systems

  • Build more in 1 month than most engineers build in 1 year. We field test weekly. Your work goes downrange, not into a filing cabinet.
  • Career velocity is real. At ~10 engineers, there are no layers between you and impact.
  • Work on a problem that actually matters. Small cheap drones are changing warfare. Our laser systems are the asymmetric answer - infinite magazine, near zero cost per shot, scalable to every base, border, facility, and truck.
  • Join the densest defense startup ecosystem in the country. California is where the next generation of defense companies are being built.
Read the original posting

From Aurelius Systems's careers page, first listed on Rolev.ai on October 17, 2026. Rolev.ai is not the employer.

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Common questions

Where is the Sr. Mechanical Engineer job at Aurelius Systems located?

This Sr. Mechanical Engineer position at Aurelius Systems is located in San Francisco, CA (On-site). Always check Aurelius Systems's application page for specific state eligibility or relocation policies.

What qualifications are required for Sr. Mechanical Engineer at Aurelius Systems?

For the Sr. Mechanical Engineer role, Aurelius Systems highlights 5+ years of relevant experience; a bachelor's degree; experience with FEA (ANSYS, Nastran, Abaqus), MIL-STD-810, thermal design for high-power systems. Rolev.ai can score your existing resume against these requirements and show any skill gaps before you apply.

How do I apply for the Sr. Mechanical Engineer position at Aurelius Systems?

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