Mechanical / Aerospace System Engineer

Location: White Oak, MD

Grade: L06 / L07

Salary range: Grade 06: $82,000 – $108,000; Grade 07: $88,000 – $125,000

Current U.S. Citizenship required.

Overview

Beyond New Horizons, LLC (BNH) has an exciting opportunity for a Mechanical or Aerospace Systems Engineer supporting TOS II at Tunnel 9 in Silver Spring, MD. The Systems Engineer will be a member of an integrated team responsible for operating and maintaining the United States Air Force Test Operations and Sustainment efforts.

Job Summary

Systems Engineers provide engineering functions to support hypersonic wind‑tunnel testing at Tunnel 9. The candidate will take ownership of major systems; coordinate facility and equipment improvement projects; follow project lifecycle (planning, budgeting, schedule, execution); perform mechanical design of tunnel components and interface hardware; develop many design drawing packages; develop/review analysis for thermo‑mechanical structural and stress analysis reports for components in the wind tunnel; and develop improvements to tunnel performance and maintainability. They will also support external customer tests by working on test article designs; creating custom solutions to test requirements; reviewing/approving test articles and supporting hardware for test safety by analyzing thermo‑mechanical structural and stress; and working with technicians to correctly prepare/install test articles in the tunnel.

Job Duties

• Respond when systems malfunction during a test, troubleshooting and directing corrective maintenance activities (or calling in the appropriate systems engineer for additional support) to ensure timely return to service.
• Perform root cause failure analyses and other equipment performance analyses when systems or processes fail and recommend remedial actions.
• Analyze and write reports on equipment design for safety reviews.
• Conduct and write up system safety hazard analyses and provide clear work instructions.
• Update and maintain system documentation for systems of responsibility.
• Develop estimates for small improvement projects and test projects.
• Communicate with internal and external customers and external model machine shops to optimize test article designs for thermo‑structural safety, instrumentation installation, ease of assembly, and rapid configuration changes between test runs.
• Design and analyze test article support hardware (e.g., stings) to meet test‑specific requirements.
• Explain to test engineers the optimal selection of sting hardware to use for tests and recommend the best options for test article configurations.
• Complete safety packages (e.g., write analysis reports, Test Hazard Analysis, and Safety Review Board presentations) prior to testing.
• Assist skilled technical staff with troubleshooting and oversee their work; provide leadership and guidance.
• Communicate clearly and utilize various methods of communication.
• Adhere to the condition of employment to wear PPE in accordance with supervisory direction and company policy.
• Perform other duties as required.

Basic Qualifications

• Grade 06: Bachelor of Science degree in Mechanical or Aerospace Engineering.
• Grade 07: Bachelor of Science degree in Mechanical or Aerospace Engineering with a minimum of 2 years of progressive and relevant experience or any equivalent combination of education and progressive relevant experience.
• Experience using solid modeling CAD software.
• Must be able to obtain and maintain a security clearance and AEDC local area network access.
• Current U.S. Citizenship required.

Preferred Qualifications

• Master of Science degree in Mechanical or Aerospace Engineering.
• Active Secret clearance.
• Hands‑on mechanical design, maintenance, or operations experience acquired through previous employment, education, or internship.
• Experience using PTC Creo CAD software.
• Experience performing finite element analysis (FEA), especially using Ansys software.

Benefits

• Competitive salaries
• Continuing education assistance
• Multiple healthcare benefits packages
• 401(k) with employer matching
• Paid time off (PTO) along with a federally recognized holiday schedule

EEO Statement

BNH is an Equal Employment Opportunity Employer. We provide equal employment opportunities to all employees and applicants for employment and prohibit discrimination and harassment of any type without regard to race, color, religion, age, sex, national origin, veteran status, and any other grounds for discrimination prohibited by applicable law.

This policy applies to all terms and conditions of employment, including recruiting, hiring, placement, promotion, termination, layoff, recall, transfer, leaves of absence, compensation, and training.

U.S. Citizenship is required. BNH will not sponsor any applicants for employment authorization or offer any immigration related support for this position.