Mechanical Engineer II, Imaging Payloads

About the role

Urban Sky is seeking a talented Mechanical Engineer to own the design, development, and fielding of advanced electro-optical imaging systems aboard our stratospheric balloon platforms. Our payloads operate in one of the harshest environments on Earth. They must survive temperature extremes, near-vacuum pressures, and high shock loads while delivering precision performance. This engineer will design systems that integrate optics (both custom and off-the-shelf), sensors, edge compute, 2-axis stabilization mechanisms, and thermal management systems into compact, flight-ready packages.

The technical challenges are broad, and so is the ownership. This is a hands-on role on a fast-paced, multidisciplinary team. Your work will span the entire development lifecycle, from initial requirements and rapid prototyping through flight testing and production transition. You will work across a range of commercial and defense products that are making real and lasting impacts today.

Key Responsibilities

• Translate product requirements and use cases into ruggedized design solutions for a diverse customer base spanning scientific, commercial, and defense applications

• Design robust, reusable payload structures with an emphasis on protecting critical components and enabling rapid turnarounds between flights. Perform structural analysis and testing to validate designs against flight load cases

• Select materials appropriate for stratospheric conditions balancing strength, thermal performance, weight, and cost constraints

• Support the design and development of 2-axis gimbal systems including structure design, motor and gear reduction mechanism selection, and feedback architecture to achieve precise pointing control

• Design and analyze thermal management solutions to maintain components within operating temperature ranges across stratospheric conditions. Develop and verify thermal models against test and flight data to build confidence in system performance

• Plan and execute benchtop testing of subsystems and prototypes to validate functionality prior to flight testing

• Conduct environmental testing including thermal cycling, vacuum exposure, and shock qualification. Support field integration and test campaigns, incorporating operational feedback into design iterations

• Maintain thorough engineering documentation including design/analysis rationale, trade studies, assembly procedures, test reports, and lessons learned to support knowledge retention and production readiness

• Generate high-quality engineering drawings with appropriate use of GD&T when necessary

• Develop and execute verification and validation plans, prepare prototypes for flight, and maintain flight safety documentation

• Analyze flight performance data to identify issues and drive design iteration. Lead post-flight hardware teardowns and failure investigations to determine root cause and inform corrective actions

• Contribute to payload architecture decisions, including evaluating new sensor technologies, identifying candidate hardware for integration, and proposing new payload concepts or capability expansions

Qualifications

• Bachelor’s degree in Mechanical Engineering or a closely related discipline; advanced degree is a plus but not required

• 2-5 years of experience in mechanical design and integration of electromechanical systems operating in real-world environments

• Proficiency in CAD software (e.g., OnShape, SolidWorks, or Fusion 360) for designing complex mechanical systems

• Strong knowledge of materials and manufacturing processes, including CNC machining, sheet metal fabrication, 3D printing, and injection molding

• Intuitive understanding of tolerance analysis, design for manufacturing (DFM), and design for assembly (DFA), with the ability to design parts and assemblies that are practical to build, inspect, and maintain

• Strong analytical and problem-solving skills, with experience using hand calculations and simulation tools to inform design decisions and the ability to systematically troubleshoot hardware issues when things don't go as planned

Nice-to-Haves / Preferred Skills

• Knowledge in optics, optomechanics, or imaging systems

• Experience working in aerospace or satellite development

• Experience developing mechanisms, motion control applications, or gimbal systems

• Familiarity with integrating mechanical systems with electronics and sensors

• Knowledge of stratospheric or high-altitude conditions and their impact on mechanical systems

• Experience with cable and wire harness design

• Familiarity with Linux or embedded systems

Requirements

• Must be a US Citizen or equivalent work authorization (Permanent Resident or otherwise eligible to access controlled US Government information)
• Must be located near Denver, CO or willing to relocate. This role is on-site at our office at 4800 Race St., Denver, CO

Benefits

• Stock Options

• Medical, Vision and Dental

• Flexible PTO schedule

• Cell Phone Bill Stipend

Urban Sky is an Equal Opportunity employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, national origin, disability, protected Veteran Status, or any other characteristic protected by applicable federal, state, or local law.