Mechanical Design Engineer - III at Catalyx Space

Catalyx Space is at the forefront of developing next-generation entry systems for space exploration. We are seeking a Senior Design Engineer (Structures) to lead the design, development, integration, and qualification of primary structures for spacecraft and reentry vehicles. This pivotal role demands a blend of hands-on CAD/FEA expertise and a comprehensive understanding of system-level ownership. The ideal candidate will possess proven experience across composite materials, pressure vessels, pyrotechnic devices, and complete spacecraft qualification processes. Bringing flight heritage experience is crucial to ensure our hardware is reliable and flight-ready.

Responsibilities

• Conceptualize and define products from inception through to flight readiness.
• Manage the overall Bill of Materials (BOM), vehicle configuration, hardware release process, and Product Lifecycle Management (PLM).
• Take full ownership of the spacecraft qualification campaign and flight acceptance testing, ensuring hardware is validated at the system level.
• Define comprehensive test campaigns for spacecraft and reentry systems.
• Establish and manage volume, mass, Center of Gravity (CG), and stiffness boundaries for cross-functional teams.
• Lead SolidWorks CAD design of primary structures and complex assemblies.
• Conduct FEA modeling and analysis using industry-standard tools like ANSYS or Abaqus.
• Define optimized assembly sequences for spacecraft structures and subsystems to facilitate efficient integration and testing.
• Oversee the end-to-end spacecraft integration process, from structural build-up to final system closeout.
• Collaborate with engineering teams to provide Design for Manufacturability (DFM) feedback and develop innovative solutions for challenging part geometries.
• Apply design principles for additive manufacturing in the development of intricate designs.
• Define and derive precise torque requirements for fasteners and joints.
• Oversee the design of Ground Support Equipment (GSE) for integration and test operations.

Qualifications

• Bachelor’s or Master’s degree in Mechanical or Aerospace Engineering, or a related technical field.
• Minimum of 5 years of professional experience in spacecraft or reentry structural design.
• Mandatory flight heritage with direct experience delivering hardware that has successfully flown.
• Expert proficiency in SolidWorks CAD software.
• Strong expertise in tolerance stack-up analysis.
• Deep knowledge of Finite Element Analysis (FEA) modeling, particularly for vibration analysis.
• Proven experience with vibration testing of aerospace structures.
• Extensive experience with composite materials, including sandwich panels and high-temperature variants.
• Demonstrated experience designing and validating pressure vessels for space applications.
• Experience integrating pyrotechnic devices into structural systems.
• Expertise in design for 3D printing and additive manufacturing.
• Experience with high-temperature fabrics, woven composites, or textile-based structures.
• Familiarity with textile engineering concepts, including weaves, stitching, and layups.

Preferred Skills

• Demonstrated ability to deliver flight-ready structural hardware.
• Background in algorithmic or generative design methods for optimizing lightweight structures.
• Excellent written and verbal communication skills.
• Flexibility to work extended hours or weekends as required by project demands.