The Senior Mechanical Test Technician is a subject matter expert responsible for independently planning, executing, and leading complex mechanical and environmental test campaigns on aerospace hardware. This role ensures high-fidelity data collection, adherence to test protocols, and cross-functional coordination with test engineering, quality, and program teams. The senior technician also mentors junior staff and drives continuous improvement in testing methods, setup practices, and safety compliance.
Key Responsibilities:
Independently execute structural, vibration (sine, random, shock), and thermal tests on flight and qualification hardware
Lead setup and operation of servo-hydraulic load frames, vibration shakers, thermal chambers, and integrated test rigs
Interpret complex test procedures, instrumentation drawings, and engineering specifications (e.g., MIL-STD-810, RTCA DO-160, NASA GEVS)
Install, calibrate, and verify instrumentation: strain gauges, accelerometers, thermocouples, displacement sensors, etc.
Operate data acquisition systems (DAQ) and analyze real-time data using platforms such as NI LabVIEW, LMS, or HBM Catman
Identify and troubleshoot complex instrumentation or equipment faults; implement corrective actions
Oversee and validate test setups, load paths, fixturing integrity, and safety interlocks
Generate accurate test documentation including setup reports, as-run logs, sensor maps, and calibration records
Mentor and train junior technicians in advanced test techniques, data handling, and FOD control
Collaborate with test engineers on test planning, instrumentation strategy, and post-test data interpretation
Ensure full compliance with quality systems, safety policies, and test standards
Key Focus Areas:
Execution and leadership of qualification, development, and acceptance tests
Instrumentation and advanced DAQ system operation
Structural, thermal, vibration testing of aerospace systems and subassemblies
Mentoring, quality assurance, and test process optimization
Qualifications & Skills:
Education:
Associate degree in mechanical/aerospace technology or equivalent technical training (required)
Bachelor’s degree in mechanical or aerospace engineering (preferred)
Experience:
7–12+ years of mechanical/environmental testing experience in aerospace, defense, or high-reliability manufacturing
Direct experience with high-value test articles (e.g., flight hardware, propulsion systems, satellite structures)
Proven track record leading test operations and collaborating with multidisciplinary engineering teams
Technical Skills:
Deep knowledge of structural load testing, vibration (sine/random/shock), and thermal/environmental test methods
Proficient in instrumentation (sensor selection, wiring, calibration, and validation)
Strong competency in DAQ platforms and test automation (e.g., LabVIEW, DEWESoft, HBM, LMS Test.Lab)
Skilled in mechanical assembly, torqueing, and fixturing for aerospace-grade components
Familiarity with AS9100, ISO 17025, and related compliance documentation
Soft Skills:
Strong leadership and mentoring abilities
Excellent troubleshooting, documentation, and cross-functional communication skills
High attention to detail and safety awareness under time-critical test conditions
Proactive in driving process improvements and standardization