Design Engineer II

Position Title: Design Engineer – Energetics & CAD/PAD

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

Employment Type: Full-Time

We design, develop, and manufacture mission-critical energetic, pyrotechnic, Cartridge Actuated Devices (CAD), and Propellant Actuated Devices (PAD). Our products serve high-consequence applications across aerospace, defense, and commercial sectors where ultra-high reliability under extreme pressure and temperature is mandatory.

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.

• Mechanical & Energetic Design: Design 3D CAD models, subassemblies, and detailed manufacturing drawings for CAD/PAD mechanisms, explosive containment housings, cutters, and release devices using Solid Works.
• 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.

• 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 Solid Works and drafting using ASME Y14.5 GD&T.
  • Practical understanding of stress/thermal analysis tools (ANSYS, Solid Works 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.

• 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, Syte Line, Epicor, Arena) and instrumentation/data acquisition tools (load cells, pressure transducers, high‑speed DAQ).
• Quality & Root Cause…