Sr HIL Engineer/Test & Automation Engineer

Job description

The Opportunity Astra is building Rocket 4, a high-cadence small-satellite launch vehicle. The Test & Launch team is the common infrastructure layer for the program – we design and operate the test stands, simulation environments, and launch systems that propulsion, avionics, GNC, and structures all depend on. This role sits at the intersection of instrumentation and control, automation software, and systems test. You will design DAQ and control architectures for test stands across the program, write the software that makes those stands run safely and repeatably, and work directly with engineering teams to define what test infrastructure they need and build it. One of the near-term workstreams for this role is the Launch System Simulator (LSS), a hardware-in-the-loop environment that runs the full avionics stack, flight software, and GNC algorithms against real-time plant models. The LSS needs an owner who can define its architecture, build out the simulation infrastructure, and integrate it into the broader test program. Beyond LSS, the role expands into I&C design and commissioning across 20+ test stands on the development roadmap. This is not a desk job. You will be in the lab, on the test stand, at the facility. You will write control logic, terminate wiring, commission sensors, troubleshoot data pipelines during a test campaign, and eventually support launch operations. Why This Role Matters Rocket 4 is a full-stack development program. Every subsystem – propulsion, avionics, GNC, structures, valves – has a test campaign running in parallel with development. The Test & Launch team is the infrastructure layer that all of them depend on. This role accelerates two things that matter for the program: it delivers the simulation and HIL infrastructure that supports flight software and GNC verification, and it deepens the team's I&C and controls capability so we can design and commission test stands as fast as the program needs them. How You'll Fulfill Your Mission Work with propulsion, avionics, and software teams to design DAQ and control system architectures for test stands across the program: instrumentation plans, I/O lists, sensor selection, signal conditioning, control cabinet layout, wiring schematics. Write and commission control logic for test stand automation: sequencing, safety interlocks, abort logic, and operator interfaces. Beckhoff TwinCAT / structured text, Python, and whatever else gets the job done. Own the Launch System Simulator from architecture through delivery: select the HIL hardware platform, build real-time plant models (propulsion, GNC, avionics), define the simulation interface to flight software, and integrate fault injection and Monte Carlo test campaigns. Partner with ground software teams on data pipeline architecture: understanding the full path from DAQ hardware through storage, processing, and visualization well enough to define requirements and troubleshoot during test campaigns. Work with propulsion, avionics, GNC, and flight software teams to design and build test infrastructure: defining requirements, validating acceptance criteria, and commissioning new stands through ORR. Support active test campaigns at Castle (Chiron engine hot-fire) and Orion (upper stage component test). Travel to Cape Canaveral for launch campaign support. Document everything: P&IDs, wiring diagrams, software architecture, commissioning procedures, and test reports in Confluence. Why We Value You 4+ years of experience in test engineering, instrumentation & control, or systems test in aerospace, defense, automotive, or a hardware-intensive field. Hands-on experience designing and commissioning DAQ and control systems: sensor selection, signal conditioning, I/O architecture, real-time control platforms. Strong controls programming background: PLC/IEC 61131-3, structured text, state machines, interlock logic. Beckhoff TwinCAT preferred. Proficient in Python for data processing, test automation, and tooling. Experience with hardware-in-the-loop (HIL) simulation: real-time plant models, simulation framework integration, test case development. Comfortable with the full hardware lifecycle: you have taken a test stand from concept through commissioning and operated it during a test campaign. Strong communicator across disciplines. You have worked directly with software, avionics, or propulsion teams and translated between hardware and software requirements. Ability to work on-site in Alameda, CA with periodic travel to test sites and Cape Canaveral. What This Role Is Not A pure software role. You will write code, but you will also be on the stand installing sensors, terminating cables, and troubleshooting hardware. A single-domain role. You will design I&C systems, build simulation infrastructure, write test procedures, and commission hardware. The variety is the feature. A large-team, well-defined-scope position. We are 9 people building 20+ test stands and launching a rocket. You will own things nobody has ever owned before. A corporate environment. The test stand you commission this quarter will be the one you run next quarter. Desired Multipliers Software-in-the-loop (SIL) simulation experience: FSW regression frameworks, plant model integration, test case development without hardware in the loop. Beckhoff EtherCAT ecosystem: TwinCAT 3, EL series I/O terminals, real-time control. Real-time plant model development for HIL simulation: Simulink Real-Time, Speedgoat, NI VeriStand, or custom frameworks. Experience with flight software or avionics test: FSW regression frameworks, bus simulation (MIL-STD-1553, SpaceWire, UART/SPI/I2C), fault injection. Industrial fieldbus and protocol experience: EtherCAT, CAN bus, Modbus, Profinet. Familiarity with data pipeline tools: InfluxDB, Grafana, Parquet, TDMS, SQL, or time-series database architectures. Propulsion or hazardous fluid system experience: LOX/LN2/GN2 handling, high-pressure pneumatics, cryogenic instrumentation. Electrical control cabinet design: layout, grounding, EMI mitigation, wire routing, panel fabrication. Startup or high-tempo development environment (SpaceX, Relativity, Firefly, Joby, Zoox, Anduril, Cruise, or similar). dSPACE, Speedgoat, or NI VeriStand platform experience. The pay range for this role is: $140,000-180,000 Salary and Benefits We're competitive in compensation and offer equity as part of the package. We have great benefits that include health, vision, dental, and 401K in comparison to other startups. We provide lunch and there's plenty of snacks and drinks to get you through the day. We will ensure that individuals with disabilities are provided reasonable accommodation to participate in the job application or interview process, to perform essential job functions, and to receive other benefits and privileges of employment. Please contact us to request accommodation. ITAR Requirements: This position requires compliance with U.S. Government space technology trade restrictions, specifically the International Trafficking in Arms Regulations (ITAR), Export Administration Regulations (EAR) and additional regulations governing satellite, launch vehicle, missile, and other related technologies. All jobs restricted by these regulations will be contingent upon the applicant’s status as a documented U.S. Person or their ability to receive a trade license from the cognizant government agency; in addition to any required company background checks and in compliance with applicable U.S. and California laws. Similarly, positions requiring the ability to work on government contracts or a security clearance are also contingent upon the applicants ability to receive the appropriate clearance and be allowed to work on U.S. government contracts. © Astra Space Operations, LLC. All rights reserved, Astra is proud to be an equal opportunity workplace. We celebrate diversity and are committed to creating an inclusive environment for all employees. We do not discriminate on the basis of race, religion, color, gender identity, sexual orientation, age, disability, veteran status, or other applicable legally protected characteristics. We encourage people of different backgrounds, experiences, abilities, and perspectives to apply. San Francisco Applicants: Astra will consider applicants with arrest and conviction records (criminal histories) in a manner consistent with the San Francisco Fair Chance Ordinance. Astra’s mission is to improve life on Earth from space by creating a healthier and more connected planet. Today, Astra offers one of the lowest cost-per-launch dedicated orbital launch services, and one of the industry’s leading flight-proven electric propulsion systems for satellites, the Astra Spacecraft Engine.