Required Skills: hardware troubleshooting, PCB, LAN, Hardware Testing, LAN, Electrical Systems

Job Description

We are seeking an experienced Flight Simulator Hardware Engineer to join the Air & Commercial Solutions (ACS) development team. The engineer will support the design, development, integration, testing, and deployment of FAA Level D Full Flight Simulators for commercial and other aviation customers.
The role focuses on developing and integrating complex simulator hardware systems, including power and control systems, motion platforms, visual display systems, avionics interfaces, mechanical assemblies, and facility infrastructure interfaces.

The engineer will work closely with Mechanical, Electrical, Systems, Software, Test, Manufacturing, Procurement, Production Planning, suppliers, and customer teams to deliver hardware solutions that meet program requirements, quality standards, schedule, and technical objectives.

Key Responsibilities:

• Perform complete hardware design and development activities for flight simulator systems and subsystems.
• Design and integrate hardware for power and control systems, motion platforms, visual display systems, avionics interfaces, and ancillary equipment.
• Develop mechanical and hardware solutions supporting full-flight and full-motion simulator systems.
• Develop CREO layouts, detailed engineering drawings, assemblies, sub-assemblies, components, ICDs, and integration test articles.
• Create and maintain BOMs, part structures, assemblies, and engineering design documentation.
• Develop hardware architectural layouts showing system-level and lower-level interfaces between systems and subsystems.
• Derive hardware and sub-tier requirements from customer, system, and program-level requirements.
• Support the development of interface control documents (ICDs) and hardware interface definitions.
• Integrate new simulator hardware with existing facility infrastructure, including HVAC, electrical distribution, grounding, fire detection, and smoke monitoring/suppression systems.
• Ensure simulator hardware designs maintain appropriate temperature and humidity stability for avionics, electronics, and motion-platform equipment.
• Support electrical and facility interfaces while ensuring compliance with applicable engineering and safety requirements.
• Perform system-level integration and hardware verification activities.
• Support technical reviews throughout the acquisition lifecycle, including SRR, PDR, CDR, and TRR.
• Prepare and review engineering documentation and technical design packages.
• Issue or support formal design-checking approvals and non-conformance reports through the PLM system.
• Use Windchill/PLM for parts, assemblies, BOMs, engineering documentation, approvals, and configuration management.
• Perform geometric dimensioning and tolerancing (GD&T) and system-level tolerance analysis.
• Support cross-functional engineering teams in resolving complex hardware design and integration issues.
• Lead or coordinate other Hardware Engineers to synchronize engineering, procurement, production planning, manufacturing, and supplier activities.
• Work with suppliers and manufacturing teams to ensure hardware designs are completed and released according to program schedules.
• Develop innovative solutions to complex engineering problems while maintaining program objectives.
• Support hardware development within an Agile engineering environment.
• Participate in requirements reviews, design reviews, integration reviews, and test readiness activities.
• Support hardware development from initial requirements through design, development, integration, testing, deployment, and production.
• Troubleshoot hardware and integration problems and develop corrective actions.
• Coordinate with Systems Engineering, Software Engineering, Test Engineering, Manufacturing Engineering, and other technical disciplines.
• Support the development and integration of flight training systems and simulator platforms.

Required Qualifications:

• Bachelor's degree in Mechanical Engineering, Electrical Engineering, Electronic Engineering, or a related engineering displane.
• Demonstrated experience developing flight simulation hardware solutions.
• Experience with mechanical/hardware design engineering principles and industry engineering practices.
• Experience developing CREO layouts and detailed engineering drawings.
• Experience creating components, subassemblies, assemblies, BOMs, and engineering documentation.
• Experience developing hardware architectures and system/subsystem interfaces.
• Experience deriving hardware requirements from customer and system-level requirements.
• Experience supporting major technical reviews such as SRR, PDR, CDR, and TRR.
• Experience working with PLM systems for engineering approvals, configuration management, and/or non-conformance processes.
• Experience working in an Agile hardware engineering/development environment.
• Ability to work effectively with cross-functional engineering and manufacturing teams.
• Candidate ability to obtain security Clearance.
• referred / Desired Qualifications :-
  • Experience with PTC Creo.
  • Experience with PTC Windchill.
  • Experience with CATIA.
  • Experience with Zuken.
  • Experience with Cameo.
  • Strong knowledge of GD&T and ASME Y14.5.
  • Experience performing complex system-level tolerance analysis.
  • Experience developing hardware architecture and high-level interconnect diagrams.
  • Experience with flight training systems.
  • Experience with full-motion flight simulators.
  • Experience with rotary-wing and/or fixed-wing aircraft.
  • Experience integrating simulator hardware with HVAC/climate-control systems.
  • Experience interfacing with facility fire detection and suppression systems.
  • Experience with modular/open systems architectures, including Service-Oriented Architecture (SOA) concepts.
  • Experience working across Systems Engineering, Hardware Engineering, Software Engineering, and Test Engineering teams.
  • Experience with development, integration, and deployment of aviation training systems.