Mechanical Engineer - Stratospheric Balloons (Aerospace)

TL;DR

Mechanical Engineer (Aerospace): Designing and analyzing structural components and thermal systems for stratospheric balloon flight vehicles with an accent on extreme environment survivability and mass optimization. Focus on translating stratospheric requirements into robust hardware, performing FEA, and managing the fabrication of electronics enclosures.

Location: Must be located near Denver, CO. Must be US Citizen or Permanent Resident.

Company

A venture-backed aerospace startup pioneering routine access to the stratosphere through the development of super-pressure balloon systems.

What you will do

• Lead mechanical design and structural analysis of airframe, gondola, and mounting hardware.
• Perform FEA and hand calculations for static, dynamic, shock, and thermal loads across the flight envelope.
• Design thermal management and electronics packaging for avionics and power systems operating in extreme cold and low pressure.
• Manage fabrication and procurement using machining, 3D printing, sheet metal, and composites.
• Build, assemble, and test hardware in lab and field environments, supporting flight operations.
• Collaborate with cross-functional teams (avionics, firmware, power) to ensure seamless vehicle integration.

Requirements

• BS/MS in Mechanical or Aerospace Engineering or equivalent experience.
• 3-10+ years of experience in mechanical design for flight, aerospace, or rugged electromechanical systems.
• Proficiency in CAD software such as OnShape, AutoCAD, or Fusion 360.
• Experience in structural analysis (FEA) and thermal design (conduction, convection, radiation).
• Knowledge of materials and manufacturing processes including machining and 3D printing.
• US Citizenship or Permanent Residency required.

Nice to have

• Experience in aerospace, high-altitude, or near-space applications.
• Experience supporting Department of Defense (DoD) programs.
• Familiarity with mass-constrained, lightweight structural design and verification.
• Expertise in integrating mechanical systems with sensors and motorized actuators.

Culture & Benefits

• Supportive team culture grounded in candor, inclusion, respect, and empowerment.
• Opportunity to work in a fast-paced environment with weekly flight vehicle launches.
• Hands-on role allowing you to design, build, and test your own hardware from lab to flight.