About the job
About Us:
Aurelius Systems is a venture capital-backed startup specializing in defense technology, dedicated to creating cutting-edge autonomous directed energy systems deployed at the edge for countering unmanned aerial systems (UAS). Our mission is to develop cost-effective, reliable, and robust laser weapon systems designed to neutralize drones.
Comprising a tight-knit team of approximately 10 engineers, ex-US military personnel, and domain experts, we are at the forefront of enhancing America's directed energy capabilities. Our ethos is inspired by Marcus Aurelius, emphasizing diligence and decisive action without excuses. We believe in the power of innovation, akin to Henry Ford's revolutionary approach to manufacturing.
In addition to our San Francisco laboratory, we have established a manufacturing hub in Detroit and conduct weekly field tests on our expansive 400-acre private range.
If you are an engineer who thrives on tangible results and prefers fieldwork over theoretical models, continue reading.
Your Role and Impact:
We are seeking a proactive Hardware Engineer to take ownership of structural and thermal designs for a groundbreaking laser weapon system being developed from the ground up. You will execute finite element analysis (FEA), devise thermal solutions, and facilitate prototype validation. This is a hands-on role where you will engage in laboratory construction, field testing, and iterative refinement of designs.
From concept to production, you will be involved every step of the way.
Your Responsibilities:
Develop and validate both passive and active thermal solutions for high-power laser modules, including conjugate heat transfer and transient thermal simulations.
Conduct stress, vibration, and modal analyses using ANSYS, SolidWorks Simulation, or equivalent tools, utilizing findings to enhance design durability, weight efficiency, and dynamic load performance.
Create and improve CAD models focusing on thermal management and structural prototypes.
Lead hands-on prototyping efforts through CNC, additive manufacturing, or rapid fabrication with a strong emphasis on testing; plan and execute vibration, shock, environmental, and robustness tests in realistic field conditions.
Conduct Design for Manufacturability (DFM) reviews to optimize geometry, tolerances, and material selections, collaborating directly with suppliers and fabricators to transition designs into production.
Evaluate metals, polymers, and composites for mechanical strength, thermal conductivity, and electromagnetic interference compatibility.
Generate Bills of Materials (BOMs), GD&T drawings, and assembly instructions while overseeing the prototype-to-production transition, ensuring compliance with industry standards.

