Position Title: Design Engineer - Energetics & CAD/PAD

Locations: Fairfield, NJ & Byram, NJ (On-site / Multi-facility travel)

Employment Type: Full-Time

Role Summary

The Design Engineer is responsible for mechanical design, energetic packaging, and project execution across the product development lifecycle. In addition to core design and analysis, this role manages project schedules, customer deliverables, and hands-on prototyping from initial concept through qualification, testing, and production transition.

Key Responsibilities

• Mechanical & Energetic Design: Design 3D CAD models, subassemblies, and detailed manufacturing drawings for CAD/PAD mechanisms, explosive containment housings, cutters, and release devices using SolidWorks.
• Technical Project Management: Own engineering project schedules, technical milestones, and action items; track design reviews (PDR/CDR), risk registers, and design deliverables for customers.
• Hands-on Prototyping & Fabrication Support: Assist with quick-turn prototype builds, fit-checks, and tooling modifications using machine shop equipment to iterate rapidly during early-stage development.
• Engineering Documentation & DFM: Apply GD&T (ASME Y14.5), draft Bills of Materials (BOMs), write technical reports/specifications, and implement Engineering Change Orders (ECOs) while optimizing for manufacturability and cost.
• Analysis & Verification: Execute structural, thermal, and pressure-vessel hand calculations and FEA simulations to verify margins under high-g shock, extreme vibration, high temperature, and high-pressure (HPHT) environments.

• Test Execution & Support: Author test plans and procedures (QTP/QTR); coordinate and oversee static, dynamic, environmental, and live energetic firing tests.
• Cross-Functional Execution: Collaborate daily with manufacturing, quality, supply chain, and machine shop technicians to ensure on-time delivery and seamless handover to AS9100-controlled production.
• Safety & Regulatory Compliance: Adhere to strict handling procedures for energetic materials in accordance with ATF, DoD, OSHA, and DOT regulations.

Required Qualifications

• Education: Bachelor's degree in Mechanical Engineering, Aerospace Engineering, Materials Science, Chemical Engineering, or a related engineering discipline.
• Experience: 2-5 years of mechanical design and project tracking experience within aerospace, defense, energetic devices, or high-reliability electro-mechanical hardware.
• Technical Skills:
• Proficiency in 3D CAD modeling SolidWorks and drafting using ASME Y14.5 GD&T.
• Practical understanding of stress/thermal analysis tools (ANSYS, SolidWorks Simulation) and material selection (aerospace alloys, corrosion-resistant steels).
• Project Management Skills: Demonstrated ability to manage project timelines using MS Project/Excel, track action items, and coordinate cross-functional deliverables to meet customer milestones.
• Legal & Regulatory Requirements:
• Must be a U.S. Person (U.S. Citizen or Permanent Resident) to satisfy ITAR and EAR requirements.
• Must be able to obtain and maintain an ATF Employee Possessor status.

Desired Skills & Experience

• Machine Shop: Hands-on experience working in a machine shop environment for prototyping, R&D fixture fabrication, and hardware modifications (e.g., manual lathe, mill, drill press, band saw, and basic shop hand tools).
• Energetics & Ballistics Knowledge: Familiarity with pyrotechnics, explosives, squibs, initiators, gas generators, or high-pressure pneumatic/hydraulic systems.
• Industry Standards: Practical exposure to military/government specifications (MIL-STD-810, MIL-DTL, NAVSEA/Air Force specs).
• Systems & Data Acquisition: Familiarity with ERP/PLM environments (SAP, SyteLine, Epicor, Arena) and instrumentation/data acquisition tools (load cells, pressure transducers, high-speed DAQ).
• Quality & Root Cause Tools: Knowledge of aerospace quality systems (AS9100) and structured problem-solving methodologies (FRACAS, 8D, Fishbone).

Work Environment & Physical Demands

• Split between office-based design/project management, machine shop/prototyping areas, and energetic test firing bays as required.
• Routine local travel between our Fairfield, NJ and Byram, NJ facilities (valid driver's license required).
• Ability to occasionally lift up to 40 lbs of test hardware, fixtures, or raw materials.

Physical Demands:

Must possess sight/hearing senses or use prosthetics that will enable these senses to function adequately so that the requirements of this position can be fully met. Physical activity includes walking, standing, bending, squatting, reaching above shoulders and lifting up to 40lbs. Must be able to drive an automobile for short and long distances. The candidate for this position may have to spend long hours using a computer, which can cause eye strain. This position will have to manage a number of requests and situations at one time. Stress may be caused by the need to complete tasks within tight deadlines.

Work Environment:

Performs office activities in a lighted and ventilated area. May be subject to changes in temperature and exposure to dust. Will be exposed to uncontrolled environmental conditions during driving. Will work in a normally acceptable office environment, with no abnormal hazards or risks. Reasonable accommodation may be made to enable individuals with disabilities to perform the essential functions. Travel between two manufacturing sites, Byram NJ and Fairfield.