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Zachary Piper Solutions is seeking a Mechanisms Engineer (AIT) to join a high‑impact team supporting the design, assembly, integration, and testing of spacecraft mechanisms for a next‑generation satellite constellation. This role is hands‑on and mission‑critical, focused on deployment systems and precision mechanisms (rather than static structures or analysis‑only work).
Job Responsibility:
Assemble, integrate, and test spacecraft mechanisms including hinges, yokes, actuators, HDRMs, release devices, and deployable booms/arms with thousands of moving parts per satellite
Perform hands‑on mechanical integration and inspection on the factory floor alongside technicians
Develop and operate ground support equipment (GSE) for vibration, shock, and thermal‑vacuum (TVAC) testing of deployment hardware
Perform tolerance stack‑up analysis to ensure alignment, prevent binding, and enable clean, reliable deployment of moving assemblies
Calculate and verify torque margins, hinge preload, and separation forces for deployment actuators and release systems
Analyze test data and define pass/fail criteria, supporting spacecraft‑level integration, launch, and on‑orbit support
Troubleshoot deployment anomalies and perform root‑cause failure investigations
drive corrective actions and design/process improvements for mechanisms that do not deploy cleanly
Collaborate cross‑functionally with structures, avionics, harness, AOCS, solar, quality, and production teams to ensure mechanism performance from design through mission deployment
Requirements:
3–10+ years of hands‑on experience with aerospace mechanisms, deployment systems, or precision moving assemblies (structures‑only or stress‑analysis‑only backgrounds will not suffice)
Proven experience assembling, integrating, and testing deployable space hardware
Strong understanding of beam loading and bending moments as they apply to deployable systems, plus torque margin, hinge preload, and tolerance stack‑ups in moving assemblies
Ability to discuss real‑world deployment failure modes and corrective actions taken on flight or qualification hardware
Proficiency with CAD tools (SolidWorks, Creo) and common test equipment
Bachelor’s degree in Mechanical, Manufacturing, Industrial, or Electrical Engineering (or equivalent practical experience)
Excellent problem‑solving and analytical skills with the ability to lead failure investigations
Flexibility for occasional weekend and early‑morning work (e.g., 4 AM deployment operations)