Mechanical Test Equipment Design Engineer, Crash Safety

As a Mechanical Test Equipment Design Engineer focused on Crash Safety at Zipline, you will develop custom equipment that enables engineers to evaluate structural integrity, crashworthiness, battery safety, and failure modes under extreme loading conditions. You will design and build robust mechanical test systems that reproduce impact, crush, abuse, vibration, thermal, and post-crash events safely and repeatably, accelerating product development while generating engineering evidence for confident design decisions. This role is open to engineers at all levels, with responsibilities and technical scope matched to your experience, from owning individual fixtures to leading the architecture of complex validation systems.

Responsibilities

• Own end-to-end development of crash safety equipment from requirements → concept → design → fabrication → commissioning → validation → continuous improvement.
• Design and develop custom mechanical test equipment supporting impact, crush, penetration, drop, abuse, fire, vibration, and structural testing of batteries and aircraft hardware.
• Design structural frames, fixtures, reaction structures, containment systems, mounting interfaces, and mechanisms capable of safely supporting high-energy testing.
• Develop systems utilizing hydraulic, pneumatic, servo-electric, and mechanical actuation to apply controlled static and dynamic loading.
• Perform engineering analyses including hand calculations, tolerance stacks, bolted joint design, load path analysis, FEA, fatigue assessments, and failure mode evaluations to ensure equipment performance and operator safety.
• Produce CAD assemblies, detailed drawings, GD&T, bills of materials, and manufacturing documentation for fabricated and machined assemblies.
• Design equipment with operator safety as a primary requirement, incorporating guarding, interlocks, energy isolation, debris containment, fire mitigation, and ergonomic considerations.
• Partner with electrical, controls, and software engineers to integrate instrumentation, sensors, data acquisition, and automation into mechanical test systems.
• Build, commission, troubleshoot, validate, and continuously improve laboratory equipment to maximize safety, repeatability, throughput, and maintainability.
• Support crash safety, abuse, and structural validation campaigns by rapidly developing new test capability and modifying existing equipment.
• Work closely with Mechanical Design, Reliability, Systems Engineering, Manufacturing, Integration & Test, and Safety teams to translate validation requirements into practical engineering solutions.
• Lead supplier engagement for fabricated equipment, machined components, welded structures, hydraulic systems, and custom mechanical assemblies.

Requirements

• Experience designing mechanical systems, structural equipment, automated machinery, manufacturing equipment, or engineering test equipment appropriate to your career level.
• Strong mechanical design skills using NX, SolidWorks, or equivalent CAD software.
• Strong engineering fundamentals including machine design, structural analysis, GD&T, tolerance analysis, hand calculations, bolted joints, fatigue, material selection, and design for manufacturing.
• Experience performing structural analysis using hand calculations and FEA.
• Familiarity with hydraulic, pneumatic, servo-electric, or other high-force actuation systems.
• Experience designing welded structures, machined assemblies, and fabricated equipment.
• Hands-on experience assembling, commissioning, troubleshooting, and improving mechanical equipment.
• Demonstrated ability to collaborate across multidisciplinary engineering teams and communicate technical tradeoffs effectively.

Nice to have

• Experience supporting crash, impact, abuse, structural, environmental, or durability testing is preferred.

Benefits

• The starting cash range for this role is $130,000 - $180,000. Please note that this is a target, starting cash range for a candidate who meets the minimum qualifications for this role. The final cash pay for this role will depend on a variety of factors, including a specific candidate's experience, qualifications, skills, working location, and projected impact. The total compensation package for this role may also include: equity compensation; discretionary annual or performance bonuses; sales incentives; benefits such as medical, dental and vision insurance; paid time off; and more.