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Key Responsibilities and Required Skills for EGSE HW Engineer

💰 $110,000 - $185,000

EngineeringHardwareAerospaceDefenseTechnology

🎯 Role Definition

As an Electrical Ground Support Equipment (EGSE) Hardware Engineer, you are the crucial link between our advanced flight hardware and successful missions. You will take ownership of the entire lifecycle of the test and checkout systems that ensure our launch vehicles, spacecraft, and avionics are mission-ready. This role involves designing complex electrical systems, from intricate PCB assemblies to large-scale power distribution racks, and seeing them through from concept to deployment on the launch pad or in the factory. You will collaborate with a multidisciplinary team of engineers to solve complex challenges, ensuring the reliability and safety of our groundbreaking technology.

📈 Career Progression

Typical Career Path

Entry Point From:

  • Junior Hardware Design Engineer
  • Avionics Test Engineer
  • Electrical Engineering New Graduate with relevant project experience

Advancement To:

  • Senior or Principal EGSE Hardware Engineer
  • Lead Systems Engineer (Test & Verification)
  • Engineering Project Manager

Lateral Moves:

  • Avionics Integration Engineer
  • Test Systems Development Engineer

Core Responsibilities

Primary Functions

  • Spearhead the end-to-end design, development, and deployment of complex Electrical Ground Support Equipment (EGSE) used for system-level testing, integration, and pre-flight checkout of aerospace vehicles and components.
  • Create and meticulously maintain comprehensive electrical design packages, including detailed schematics, wiring diagrams, harness drawings, and bills of materials (BOMs) using CAD software like Altium Designer or Zuken E3.
  • Drive the full project lifecycle for EGSE systems, from initial requirements gathering and concept definition through detailed design, fabrication, assembly, integration, and final commissioning at test sites.
  • Perform rigorous trade studies and select appropriate Commercial-Off-The-Shelf (COTS) components, such as power supplies, data acquisition modules, and instrumentation, ensuring they meet stringent performance and environmental requirements.
  • Conduct in-depth circuit analysis, modeling, and simulation (e.g., SPICE) to verify design robustness, signal integrity, and power efficiency before committing to hardware fabrication.
  • Oversee the manufacturing, assembly, and integration of EGSE hardware, working closely with internal technicians and external vendors to ensure quality and adherence to design specifications.
  • Develop and execute comprehensive verification and validation test plans, procedures, and reports to qualify EGSE performance and certify its readiness for operational use.
  • Act as the primary technical point of contact for troubleshooting and resolving complex hardware issues encountered during avionics integration, system-level testing, and launch campaigns.
  • Collaborate extensively with avionics, software, systems, and manufacturing engineering teams to ensure seamless integration of EGSE with flight hardware and test software.
  • Design and implement robust power distribution systems for test cells and launch facilities, ensuring safe and reliable power for all ground and flight hardware.
  • Architect and integrate advanced Data Acquisition (DAQ) systems and sensor instrumentation to capture critical test data with high fidelity and accuracy.
  • Lead the design, layout, and fabrication of custom Printed Circuit Boards (PCBs) for signal conditioning, control logic, and specialized interface functions within the EGSE.
  • Manage relationships with external suppliers and fabrication houses, overseeing procurement, quality control, and delivery schedules for critical components and assemblies.
  • Provide hands-on support at manufacturing facilities, integration labs, and launch sites, sometimes requiring travel and work in dynamic, high-stakes environments.
  • Ensure all designs comply with relevant industry and safety standards, including IPC-A-610/620 for workmanship, and grounding/bonding best practices for hazardous environments.
  • Author and maintain critical documentation, including design review presentations, system architecture diagrams, user manuals, and maintenance procedures for all developed hardware.
  • Lead and participate in formal design reviews (PDR, CDR), presenting design concepts, analysis results, and validation data to peers and leadership for approval.
  • Champion Design for Manufacturability (DFM) and Design for Serviceability (DFS) principles to create EGSE that is not only high-performing but also efficient to build and maintain.
  • Develop hardware abstraction layers and interface control documents (ICDs) that clearly define the boundary between the EGSE hardware and the test automation software.
  • Define and manage system-level grounding architecture, bonding strategies, and EMI/EMC mitigation plans to ensure signal integrity and system safety in noisy electrical environments.

Secondary Functions

  • Support ad-hoc data requests and perform exploratory data analysis on test results to identify trends and anomalies.
  • Contribute to the organization's long-term EGSE technology strategy and roadmap development.
  • Collaborate with business units and program management to translate future mission needs into concrete engineering requirements for next-generation test systems.
  • Participate in sprint planning, stand-ups, and other agile ceremonies within the integrated product team.

Required Skills & Competencies

Hard Skills (Technical)

  • Schematic Capture & PCB Layout: Expert-level proficiency with EDA tools such as Altium Designer, Zuken E3, OrCAD, or Mentor Graphics.
  • Circuit Design & Analysis: Strong skills in analog, digital, and mixed-signal circuit design, along with simulation experience using SPICE or similar tools.
  • Data Acquisition (DAQ) Systems: Hands-on experience with DAQ hardware (e.g., National Instruments, C-series modules) and instrumentation for measuring voltage, current, temperature, and pressure.
  • Communication Protocols: Deep understanding of serial communication standards (RS-422/485, UART, SPI, I2C), industrial buses (CAN, Modbus), and networking (Ethernet, TCP/IP).
  • Power Systems: Experience designing and implementing power distribution units, selecting circuit protection, and managing AC/DC power electronics.
  • Test Equipment Proficiency: Expertise in using and interpreting results from lab equipment like oscilloscopes, digital multimeters (DMMs), logic analyzers, and power supplies for debug and verification.
  • IPC Standards: Working knowledge of IPC-A-610 (Acceptability of Electronic Assemblies) and IPC/WHMA-A-620 (Requirements for Cable and Wire Harness Assemblies).
  • Programming/Scripting: Basic proficiency in a scripting language like Python or a test environment like LabVIEW for hardware checkout and simple automation tasks.
  • System-Level Integration: Proven ability to integrate complex electrical and electronic systems, manage interfaces, and troubleshoot system-level issues.
  • 3D/2D CAD: Familiarity with mechanical CAD software (e.g., SolidWorks, AutoCAD) for enclosure design and creating rack elevation drawings.

Soft Skills

  • Complex Problem-Solving: Ability to diagnose and resolve challenging technical issues in a logical and systematic manner, often under pressure.
  • Effective Communication: Excellent written and verbal communication skills, capable of conveying complex technical concepts to a diverse audience.
  • Collaboration & Teamwork: A strong team player who can work effectively in a fast-paced, cross-functional engineering environment.
  • Ownership & Accountability: A proactive, self-starting mentality with a strong sense of ownership and responsibility for project outcomes.
  • Adaptability: Ability to thrive in a dynamic environment where priorities and requirements can evolve rapidly.

Education & Experience

Educational Background

Minimum Education:

  • Bachelor of Science (B.S.) in Electrical Engineering, Computer Engineering, or a closely related technical discipline.

Preferred Education:

  • Master of Science (M.S.) in Electrical Engineering with a focus on electronics, power systems, or embedded systems.

Relevant Fields of Study:

  • Electrical Engineering
  • Computer Engineering
  • Aerospace Engineering (with an electronics focus)

Experience Requirements

Typical Experience Range: 3-8 years of professional experience in a relevant hardware design or test engineering role.

Preferred: 5+ years of direct experience designing, building, and commissioning electrical ground support equipment, test stands, or similar complex electrical systems within the aerospace, defense, or automotive industries.

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