Instrumentation & Controls Engineer III-Ground Systems

Job description

ABOUT FIREFLY AEROSPACE Firefly Aerospace is a space and defense technology company that enables our world to launch, land, and operate in space – anywhere, anytime. As the partner of choice for critical space missions, Firefly is the only commercial company to launch a satellite to orbit with 24-hour notice and the only company to achieve a successful Moon landing. Our launch vehicles, lunar landers, and orbital vehicles provide government and commercial customers with full mission services from low Earth orbit to the Moon and beyond. Headquartered in north Austin, Texas, Firefly is looking for passionate, hardworking innovators to join our team and help fuel our successful trajectory into space. About the Role Join Firefly's Ground Systems team as a Level III Instrumentation & Controls Engineer and become the technical authority for the systems that make launch, orbit, and landing possible. This isn't theoretical engineering—it's expert-level design, technical leadership, and strategic direction for the control systems and instrumentation that monitor rocket engines, manage cryogenic propellants, and enable rapid-fire test campaigns across all of Firefly’s programs. As a Level III engineer, you are the subject matter expert and technical leader. You'll architect complete control system solutions from concept through commissioning, lead complex projects and multiple engineers on time-sensitive initiatives, and serve as the go-to authority when the toughest technical challenges arise. Your control architectures will span all of Firefly's test stands, test fixtures, and launch sites. Your technical decisions will influence and shape the evolution of rapidly evolving launch and in-space programs. Your expertise will guide the next generation of engineers developing Firefly's ground infrastructure. This role demands technical mastery and leadership. You'll need deep expertise in PLCs, HMIs, data acquisition, and instrumentation—but also the strategic vision to set technical direction, the leadership skills to guide project teams, and the business acumen to support project execution and customer engagement. You'll work at the highest technical level—defining standards, driving innovation, developing roadmaps, and representing Firefly's I&C capabilities to internal and external stakeholders. You'll lead technical teams through the most complex challenges, make architectural decisions that impact multiple programs, and resolve problems that other engineers escalate to you. When a novel test requirement demands a control solution that doesn't exist yet, you'll architect it. When a major customer has concerns about data integrity or performance, you'll be in the room explaining our approach. When a critical project needs expert leadership to stay on track, you'll take the reins. If you're a recognized expert in instrumentation and controls who's ready to shape the technical direction of a growing space company, mentor the next generation of engineers, and see your architectural vision enable humanity's expansion into space, this is your opportunity. Key Responsibilities Technical Leadership & Subject Matter Expertise: Serve as subject matter expert (SME) for instrumentation and controls across Firefly Lead small technical teams of 1-2 engineers on specific, complex, or time-sensitive projects and initiatives Create and maintain procedures and standards for design, fabrication, and activation of control systems and control hardware Drive innovation in control system methodologies, tools, and approaches Develop long-term technical roadmaps for I&C capabilities and infrastructure Architect control system solutions for novel applications and complex technical challenges Provide technical authority and final design approval for critical control systems Serve as technical escalation point for complex troubleshooting and problem resolution Represent Firefly I&C capabilities in technical reviews, working groups, and industry forums Strategic Planning & Business Development: Participate in proposal development and provide technical input for new business opportunities Interface with internal and external customers to understand and resolve technical challenges Support cost estimation and technical risk assessment for new projects Contribute to technical strategy and capability development planning Identify opportunities for technology advancement and competitive differentiation Develop relationships with vendors, technology providers, and industry partners Control System Design & Implementation: Design, develop, test, and introduce controls, human-machine interfaces, data acquisition, and PLC systems for equipment involving mechanical, electrical, electronic controls, and fluid handling systems Design and implement PLC-based control systems for test stands, launch infrastructure, and ground support equipment Develop control logic, ladder logic, and structured text programming for Allen-Bradley, Siemens, or similar PLC platforms Design and configure HMIs (Human Machine Interfaces) for operator control and system monitoring Create control system architectures including I/O mapping, network topology, and control panel layouts Design interlock logic and safety systems to protect personnel, equipment, and flight hardware Develop automated sequencing for propellant loading, engine testing, and vehicle processing operations Implement motion control systems for valves, actuators, and positioning systems Develop SCADA systems for monitoring and control of distributed ground support equipment Instrumentation & Data Acquisition: Specify, select, and integrate sensors including thermocouples, RTDs, pressure transducers, flow meters, strain gauges, load cells, and position encoders Design signal conditioning circuits and amplification systems for sensor interfaces Configure data acquisition systems using National Instruments hardware (cRIO, CompactRIO, PXI) or similar platforms Develop LabVIEW or Python scripts for automated data collection and analysis Design instrumentation layouts and cable routing for test stands and launch facilities Calibrate instrumentation and maintain calibration records per AS9100 requirements Implement high-speed data acquisition for transient measurements during engine firings Electrical Design & Documentation: Generate instrumentation and control system drawing packages for projects including control and I/O diagrams, instrument and control cable schedules, instrument loop diagrams, junction box wiring diagrams, control panel layout and wiring diagrams Create electrical drawings including single-line diagrams, control schematics, wiring diagrams, panel layouts, and conduit routing plans Design control panels including power distribution, circuit protection, terminal blocks, and component mounting Specify electrical components including breakers, contactors, relays, power supplies, and signal converters Review and approve electrical installation work for compliance with design intent and electrical codes Maintain as-built documentation and configuration control of electrical systems Procurement & Vendor Management: Obtain and evaluate vendor quotations for all required instrumentation and electrical equipment to be purchased for projects Prepare technical specifications and requisitions for control system components Coordinate with procurement team to ensure timely delivery of materials Review vendor submittals, datasheets, and technical documentation for compliance with specifications Manage relationships with equipment vendors and system integrators Evaluate new technologies and products for potential application in ground systems Testing & Development: Create and conduct in-house testing and development of equipment Develop test procedures and acceptance criteria for control system validation Perform bench testing of control panels, instrumentation, and data acquisition systems Conduct proof-of-concept testing for new control strategies and technologies Validate software and firmware before deployment to operational systems Installation, Commissioning & Testing: Handle all controls and communications aspects of installation, including pre-installation site surveys, controls installation preparedness, and equipment commissioning Support installation activities including panel fabrication, cable pulling, termination, and system integration Assist in building of panels and other electrical hardware based on drawings Perform Factory Acceptance Testing (FAT) and Site Acceptance Testing (SAT) of control systems Commission control systems including I/O checkout, loop tuning, and functional verification Validate control logic through simulation and dry-run testing before live operations Troubleshoot electrical and control system issues during installation and commissioning Provide engineering support to technicians during installation and commissioning activities Support operational readiness reviews and safety reviews for new systems Test Operations Support: Work with launch and test personnel in performing checkouts and commissioning of installed instrumentation and electrical systems, including calibration and/or configuration of instrument devices Perform site checkouts for test and launch operations and support launch and test day as needed Support test campaigns by operating control systems, monitoring data acquisition, and troubleshooting real-time issues Provide on-call engineering support for test operations including evenings and weekends as needed Diagnose and resolve control system anomalies during test operations with minimal downtime Review test data and provide feedback on instrumentation performance and data quality Implement rapid modifications to control systems to support evolving test requirements Collaborate with test engineers to optimize test procedures and system performance Cross-Functional Collaboration: Work with operations team to ensure compliance with all regulatory and safety requirements, proper and timely build of equipment, and cost reduction in design Work closely with mechanical, fluids, structures, and software engineers to define system requirements Work with multidisciplinary teams and communicate effectively between different schools of engineering Participate in design reviews including PDR, CDR, and operational readiness reviews Coordinate with operations teams to understand operational needs and constraints Interface with vendors and contractors for equipment procurement and installation Provide personnel training on control system operation Provide technical input to project managers on schedule, cost, and technical risk Mentorship & Technical Leadership: Mentor Level I and Level II engineers and technicians on control system design, PLC programming, and instrumentation best practices Review technical work products from junior engineers including drawings, calculations, and code Lead small technical projects or subsystem design efforts Contribute to development of engineering standards, templates, and best practices Support continuous improvement of engineering processes and tools Required Qualifications Bachelor's degree in Electrical, Mechanical, Computer, Aerospace, Controls, Instrumentation, or related Engineering or technical discipline Minimum 3-5 years of experience in instrumentation and controls engineering for industrial systems, test facilities, or ground support equipment 3-5 years of recent experience in a professional setting outside the classroom in control systems for chemical/oil facilities (SCADA), aerospace ground or vehicle control systems, or similar industrial applications Hands-on experience programming PLCs (Allen-Bradley, Siemens, or similar platforms) using ladder logic and structured text Experience designing and configuring HMIs for industrial control applications Strong understanding of instrumentation including sensor selection, signal conditioning, and calibration Working knowledge of common electrical sensors (thermocouples, RTDs, strain gauges, encoders, etc.) Proficiency with data acquisition systems, preferably National Instruments hardware and LabVIEW Ability to read and create electrical schematics, P&IDs, wiring diagrams, and control system documentation Experience with industrial communication protocols (Ethernet/IP, Modbus, Profibus, DeviceNet) Strong electrical fundamentals including circuit analysis, power systems, and analog/digital electronics Proficiency with AutoCAD Electrical or similar electrical design software Experience with commissioning and troubleshooting of control systems in operational environments Hands-on experience with multimeters, oscilloscopes, signal generators, and calibration equipment Ability to learn quickly, take accountability, and self-motivate Good oral and written communication skills Strong problem-solving skills and ability to troubleshoot complex electrical and control issues Effective communication skills for technical documentation and cross-functional collaboration Flexibility to support test operations including extended hours and weekend work as needed U.S. Person status required (U.S. Citizen, Lawful Permanent Resident, Refugee, or Asylee) due to ITAR/EAR requirements Preferred Qualifications Master's degree in Electrical Engineering or Controls Engineering 5+ years of experience in aerospace, defense, petrochemical, or similar high-reliability industries Experience with rocket engine test stands, launch pad control systems, or propulsion test facilities Knowledge of cryogenic fluid systems, high-pressure gas systems, and propellant handling operations Experience with National Instruments cRIO or CompactRIO systems and LabVIEW Real-Time programming Proficiency with Python for automation scripting and data analysis SCADA creation or management experience for distributed control systems Ability to assist in panel assembly and hands-on fabrication of electrical hardware Familiarity with ISO, IEEE, NFPA, ANSI, and EIA codes and electrical codes and requirements Knowledge of NFPA 70 (NEC), NFPA 79, and UL 508A electrical standards Understanding of EMI/EMC considerations and design practices Experience with motion control systems and servo drives Familiarity with SCADA systems and industrial networking infrastructure Experience with RF systems, telemetry, or wireless instrumentation Understanding of hazardous location electrical design (Class I, Div 1/2) Knowledge of AS9100 or ISO 9001 quality management systems Previous experience supporting test campaigns or launch operations PE license or EIT certification Six Sigma or Lean certification Firefly offers outstanding benefits for our employees, including generous health, dental and vision plans with low plan deductibles, parental leave, relocation benefits, educational reimbursement, short term disability, and flexible PTO options. To conform to U.S. Government space technology export regulations, including the International Traffic in Arms Regulations (ITAR) you must be a U.S. citizen, lawful permanent resident of the U.S., protected individual as defined by 8 U.S.C. 1324b(a)(3), or eligible to obtain the required authorizations from the U.S. Department of State. Firefly Aerospace, Inc. is an Equal Opportunity Employer; employment with Firefly is governed based on merit, competence and qualifications and will not be influenced in any manner by race, color, religion, gender, national origin/ethnicity, veteran status, disability status, age, sexual orientation, gender identity, marital status, mental or physical disability or any other legally protected status.