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Develops and deploys mechanical test fixtures and systems for product development and mass production. Responsibilities include translating test requirements into robust designs, applying tolerance analysis and GD&T, collaborating with contract manufacturers, leading fixture debugging and root-cause investigations, maintaining CAD and production documentation, and supporting NPI and production builds. The role also integrates electrical and instrumentation elements, evaluates fixture capability using manufacturing data and statistical methods, and drives cross-functional fixture improvements.
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Artificial Intelligence • Computer Vision • Hardware • Robotics • Transportation • Automation • Manufacturing
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Design and integrate avionics for aircraft, oversee system integration tasks, support testing activities, and prepare mechanical design documentation.
About Merlin:
Merlin (NASDAQ: MRLN) is a publicly traded aerospace and defense company building a non-human pilot to deliver full-stack autonomy for any aircraft from takeoff to touchdown. The Merlin Pilot autonomy system powers a growing range of aircraft and mission profiles and has been proven through hundreds of autonomous flights from Merlin's global flight test facilities, including Kerikeri, New Zealand; Quonset Point, Rhode Island; and soon, Bedford, Massachusetts. Headquartered in Boston, Merlin is expanding its organization to accelerate the development and deployment of its autonomy platform, helping customers solve some of aviation's most pressing challenges, from pilot shortages to improving flight safety. Backed by some of the world's leading investors prior to its public listing, Merlin continues to advance the certification and commercialization of autonomous flight across commercial and defense aviation.
About You:
You are a hands-on mechanical engineer who thrives in fast-paced, highly collaborative startup environments and is excited by the challenge of building next-generation autonomous aerospace systems. You bring experience designing, developing, and testing complex mechanical hardware for aerospace, robotics, or other highly regulated high-performance industries.
You are comfortable owning projects from concept through production and enjoy working closely with cross-functional teams including avionics, flight controls, systems engineering, and flight test. You are detail-oriented, technically curious, and motivated by solving difficult engineering problems under aggressive timelines. You balance analytical rigor with practical execution and are energized by working on products that push the boundaries of autonomous flight.
Responsibilities:
- Design, develop, and release mechanical components and assemblies for autonomous aircraft systems including structures, enclosures, mounts, actuation systems, and integration hardware
- Support the full product development lifecycle from concept generation, CAD modeling, prototyping, testing, design iteration, and production release
- Perform mechanical analysis (structural, thermal, vibration, tolerance, etc.) to validate designs and ensure system reliability
- Collaborate closely with electrical, avionics, software, systems, manufacturing, and flight test teams to integrate hardware into aircraft platforms
- Develop engineering documentation including drawings, BOMs, test plans, validation reports, and manufacturing instructions
- Support prototype builds, integration activities, ground testing, and flight test operations
- Drive root cause investigations and implement corrective actions for mechanical failures and design issues
- Work with suppliers and manufacturing partners to support fabrication, qualification, and production readiness
- Contribute to continuous improvement initiatives focused on performance, manufacturability, weight reduction, reliability, and cost optimization
- Operate effectively in a rapid development environment with evolving priorities and tight execution timelines
Qualifications:
- Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, or related engineering discipline
- 3–5 years of professional mechanical engineering experience in aerospace, autonomous systems, robotics, automotive, defense, or other high-performance hardware industries
- Strong proficiency with CAD software such as Siemens NX, CATIA, SolidWorks, or similar 3D modeling tools
- Experience designing mechanical systems for dynamic or mission-critical environments
- Knowledge of mechanical analysis methods including stress, thermal, vibration, and tolerance analysis
- Experience supporting prototype development, integration, and hardware testing activities
- Familiarity with aerospace materials, manufacturing processes, and design for manufacturability principles
- Strong understanding of engineering documentation and configuration control processes
- Ability to troubleshoot complex mechanical issues and drive solutions in a collaborative environment
- Excellent communication skills and ability to work cross-functionally across engineering and operations teams
- Experience in autonomous aircraft, UAVs, eVTOL, robotics, or flight hardware development is highly preferred
- Hands-on mechatronics experience is a plus
- Familiarity with FAA certification environments, aerospace standards, or regulated development processes is a plus
Merlin Labs offers an innovative, entrepreneurial, and team-focused startup environment. We also offer a top-notch benefits package (health, dental, life, unlimited vacation, and 401k with match) and work/life integration. Being part of the Merlin team allows you to become part of a small team that supports professional development while working together to achieve our mission.
Merlin Labs is an equal opportunity employer and values diversity. We do not discriminate on the basis of race, religion, color, national origin, genetic information, sex (including pregnancy), gender, gender identity and expression, sexual orientation, age, marital status, military service or obligation or disability status, or any other characteristic protected by law. All job offers are contingent upon the candidate passing background and reference checks.
At this time, we are unable to provide visa sponsorship or consider candidates who require visa transfers. Applicants must be authorized to work in the United States without the need for visa sponsorship now or in the future.
In compliance with federal law, all persons hired will be required to verify identity and eligibility to work in the United States and to complete the required employment eligibility verification form upon hire.
If you require reasonable accommodation in completing an application, interviewing, completing any pre-employment testing, or otherwise participating in the employee selection process, please direct your inquiries to: [email protected]
Merlin Labs does not accept unsolicited resumes from any source other than directly from candidates.
What you need to know about the Boston Tech Scene
Boston is a powerhouse for technology innovation thanks to world-class research universities like MIT and Harvard and a robust pipeline of venture capital investment. Host to the first telephone call and one of the first general-purpose computers ever put into use, Boston is now a hub for biotechnology, robotics and artificial intelligence — though it’s also home to several B2B software giants. So it’s no surprise that the city consistently ranks among the greatest startup ecosystems in the world.
Key Facts About Boston Tech
- Number of Tech Workers: 269,000; 9.4% of overall workforce (2024 CompTIA survey)
- Major Tech Employers: Thermo Fisher Scientific, Toast, Klaviyo, HubSpot, DraftKings
- Key Industries: Artificial intelligence, biotechnology, robotics, software, aerospace
- Funding Landscape: $15.7 billion in venture capital funding in 2024 (Pitchbook)
- Notable Investors: Summit Partners, Volition Capital, Bain Capital Ventures, MassVentures, Highland Capital Partners
- Research Centers and Universities: MIT, Harvard University, Boston College, Tufts University, Boston University, Northeastern University, Smithsonian Astrophysical Observatory, National Bureau of Economic Research, Broad Institute, Lowell Center for Space Science & Technology, National Emerging Infectious Diseases Laboratories
