Flight Simulator Hardware Engineer

Position:

Flight Simulator Hardware EngineerLocation:

Bethesda, MDAbout the RoleWe are seeking an experienced Hardware Engineer to join a multidisciplinary development team responsible for delivering advanced FAA Level D Full Flight Simulators. The successful candidate will lead the design, integration, and deployment of simulator hardware systems while collaborating with engineering, manufacturing, suppliers, and program stakeholders to ensure successful execution throughout the product lifecycle.

This role requires expertise in hardware architecture, mechanical and electrical integration, flight simulation systems, and facility infrastructure integration. The engineer will drive innovative technical solutions and support major program milestones from concept through deployment.

Responsibilities§ Design, develop, and integrate hardware solutions for: Power distribution and control systems, Motion platform systems, Visual display systems, Avionics interfaces, Training simulator support equipment§ Lead end-to-end hardware integration activities between simulator systems and facility infrastructure, including HVAC systems, Electrical distribution systems, Grounding and bonding, Fire detection and smoke monitoring systems§ Develop hardware architectures and interface definitions between systems and subsystems.§ Derive hardware and lower-level requirements from customer, system, and platform requirements.§ Create and maintain engineering documentation, including Interface Control Documents (ICDs), Component and assembly drawings, Hardware architecture diagrams, Design specifications, Bills of Materials (BOMs)§ Generate detailed layouts, models, assemblies, and manufacturing drawings using CAD tools.§ Manage part creation, configuration control, and product lifecycle documentation within PLM environments.§ Review designs and provide formal engineering approvals, design checks, and non-conformance dispositions.§ Collaborate with cross-functional teams including Systems Engineering, Software Engineering, Manufacturing, Procurement, Test Engineering, and Program Management.§ Support major technical reviews, including: System Requirements Review (SRR), Preliminary Design Review (PDR), Critical Design Review (CDR), Test Readiness Review (TRR)§ Provide technical leadership and mentorship to hardware engineering team members.§ Drive hardware development activities within Agile development environments. Minimum Qualifications

• Bachelor's degree in Mechanical Engineering, Electrical Engineering, Electronics Engineering, Aerospace Engineering, or a related technical discipline.
• 9+ years of experience designing and developing complex hardware systems.
• 9+ years of experience supporting flight simulation, training systems, aerospace, defense, or related high-reliability platforms.
• Experience developing hardware architectures and interface definitions across integrated systems.
• Experience deriving hardware requirements from customer and system-level requirements.
• Experience creating BOMs, engineering documentation, assemblies, and product definitions.
• Strong background in mechanical and/or electrical hardware design.
• Experience supporting hardware development throughout the full product lifecycle.
• Experience working within Agile development environments.
• Demonstrated ability to lead cross-functional teams through major engineering reviews and program milestones. Preferred Qualifications
• Experience with FAA-certified flight training devices and Level D Full Flight Simulators.
• Experience with rotary-wing and/or fixed-wing aircraft platforms.
• Proficiency with engineering and PLM tools such as: Creo, Windchill, CATIA, Zuken, Cameo Systems Modeler
• Knowledge of Geometric Dimensioning and Tolerancing (GD&T) in accordance with

ASME Y14.5.

• Experience performing complex tolerance analyses for integrated hardware systems.
• Experience developing hardware architectures, interconnect solutions, and subsystem interface specifications.
• Experience integrating simulator hardware into existing facilities while maintaining environmental and operational requirements.
• Experience adapting hardware solutions to climate control systems to ensure temperature and humidity stability for avionics and motion systems.
• Experience integrating products with fire detection, monitoring, and suppression systems.
• Experience with modular open systems architectures (MOSA) and service-oriented architectures (SOA).
• Experience supporting development of software-intensive systems across Hardware, Software, Systems Engineering, and Test disciplines.

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