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Senior Design Engineer



Boston, MA, USA · Boston, MA, USA · Remote
Posted on Wednesday, May 22, 2024

Why AeroShield might be great for you

AeroShield is a collaborative team of 17+ people bound by a mission to deliver innovative new materials to make our lives more sustainable. Too much energy is wasted by poor building insulation, especially poorly insulated windows and we are on a mission change that. AeroShield is developing super-insulating, transparent inserts for windows based on aerogels, bringing state-of-the-art thermal comfort and energy efficiency into buildings at an affordable price.

You'll become part of a growing team and collaborating closely to tackle impactful challenges. In this environment, you'll be surrounded by talented individuals who excel in their roles and are supportive team players.

Our goal is to ensure that our super-insulating silica aerogel, the first truly transparent aerogel, is widely adopted to enable affordable, high-performance windows.

What we are looking for in a Senior Design Engineer

We're in search of an Engineer who enjoys the autonomy offered by a dynamic small startup environment and takes initiative to find new learning opportunities. This person should be highly organized and detail oriented, have a passion for learning new skills and processes, and be able to work collaboratively with others.

We highly value a positive team culture and are looking for someone who wants to be part of continuously enhancing this culture - ideally playing an active role in this as the company grows. This person should embody AeroShield’s values of Understand & Improve, Value People, and Act Sustainably.

The Senior Design Engineer will own the design and development of equipment for the Process Development and Production (PDP) team. Their primary tasks will be equipment design, manufacturing improvements, testing and validation optimization. This role will be instrumental in design, fabrication and validation of AeroShield’s equipment to scale our state-of-the-art aerogel manufacturing process both in size and volume.

The ideal candidate has significant experience with 3D CAD systems such as Fusion 360 (ideally), SolidWorks or Inventor, and have experience in the process of turning a concept into reality. They enjoy working with their hands to build and test their designs, and they thrive in fast-paced environments where the results of their work play an important role in advancing new technologies to market.

Details of position:

  • Full-time with 3-5 days/week in person @ R&D facility in Waltham, MA
  • Reports to Lead Process Engineer
    • Leads the design and development of new processes for casting and molding large aerogel sheets, from conceptualization to implementation.
    • Collaborate closely with cross-functional teams including research and development, manufacturing, and product teams to ensure alignment with company objectives.
    • Utilize 3D CAD software to create detailed designs, schematics, and prototypes for manufacturing equipment and processes.
    • Lead the fabrication and assembly of prototypes, ensuring adherence to design specifications and quality standards.
    • Works hands on in the machine shop and lab to build, modify and assemble systems and equipment for PDP team.
  • Optimize existing processes to improve efficiency, productivity, and cost-effectiveness.
    • Occasional laboratory experimentation and testing to validate designs and assist PDP team in production activities. Commitment to safety is paramount.
  • Knowledge of engineering drawing best practices, tolerance stack-up analysis, machine design and Finite Element Analysis (FEA) for stress, Factor of safety (FOS) and fatigue analysis are a plus.

Additional activities depending on experience and interests:

  • Wiring, piping & testing
  • Familiarity with automation and controls
  • Robotics in manufacturing

This role requires candidates to be on-site with most work being conducted in-person at our facility in Hyde Park, MA and from Q3 2024 at our new facility in Waltham, MA.


Many great team members do not fit a “standard blueprint”. Even if you do not fit all aspects listed below, but feel that you can contribute to AeroShield’s team, please do not hesitate to apply or to reach out with questions. Great candidates for this role enjoy learning quickly, are excited about new technologies, and possess a technical background through school and work experience.

  • Bachelor’s or Masters in Mechanical Engineering, Chemical Engineering, Industrial Engineering or related field
  • Minimum of 5 years of experience in design and engineering, preferably in manufacturing or related industries.
  • Strong knowledge of 3D CAD, engineering drawings, & machine design
    • Background with design-build engineering projects, understanding full life cycle of a project
    • Strong project management skills and experience working with many stakeholders to deliver a project
    • Strong interpersonal skills including the ability to listen, distill information, consult, and suggest new approaches
  • Hands-on experience a must

Bonus skills:

  • Experience in automation & programming (python, C++, etc.)
  • Experience working hands-on with machinery (mill, lathe, drill press, band saw etc.)
  • PLCs and industrial automation

How to Apply

Please submit your resume via our career portal at:

Additionally, please include a few sentences or paragraphs about why you are interested in this role and why it looks like a good fit for you. This does not need to be a cover letter or anything formal, we just want to see what excites you about working at AeroShield!

Contact for questions: Zack Goodman

About AeroShield

AeroShield manufactures a super-insulating nanoporous form of glass for energy efficient windows. Based on silica aerogel technology, AeroShield is more transparent than glass and twice as insulating as air, enabling windows that are 50% more energy efficient and cost-effective, with the potential to save billions of dollars in energy. See and for more details.