New offer - be the first one to apply!
July 10, 2026
Flight Test Instrumentation Engineer
Mid
North Kingstown, RI
Merlin is a venture backed aerospace startup building a non-human pilot to enable both reduced crew and uncrewed flight. Backed by leading investors, Merlin is scaling alongside customers to leverage autonomy to solve aviation challenges.
About You
As a Flight Test Instrumentation (FTI) Engineer, you will serve as a key technical contributor within the Flight Test team, working closely with instrumentation technicians, flight test engineers (FTEs), Test Directors, test pilots, and various engineering groups to plan, design, and execute complex flight test programs.
The company advances aviation by bringing in high-level automation that reduces pilot workload.
Responsibilities
As a Flight Test Instrumentation Engineer, you'll develop and integrate the flight test instrumentation (FTI) systems that enable safe, efficient flight testing. You'll design data acquisition architectures, support aircraft integration, and ensure high-quality test data from installation through post-flight analysis.
- Design, integrate, and validate flight test instrumentation and data acquisition systems.
- Develop instrumentation architectures, system requirements, and sensor layouts to support flight and ground testing.
- Partner with engineering teams to integrate instrumentation into aircraft and support system verification.
- Execute pre-flight instrumentation checks, calibration, and FTI software configuration to ensure reliable data collection.
- Support technicians and mechanics during instrumentation installation, checkout, and troubleshooting.
- Maintain instrumentation configuration control, calibration records, and engineering documentation.
- Create wiring diagrams, installation drawings, test procedures, and configuration records.
- Troubleshoot instrumentation issues and improve system performance and data quality.
- Ensure compliance with engineering, safety, and airworthiness standards throughout flight test operations.
Qualifications
- Experience with flight test instrumentation (FTI), data acquisition systems, and real-time telemetry.
- Hands-on experience with instrumentation sensors, including strain gauges, accelerometers, pressure transducers, thermocouples, and displacement sensors.
- Ability to read and develop electrical schematics, wiring diagrams, and system architecture drawings.
- Strong understanding of electrical and electronic fundamentals, including power distribution, signal conditioning, and circuit analysis.
- Experience using electronic test and diagnostic equipment, such as oscilloscopes, signal generators, spectrum analyzers, and data acquisition tools.
- Ability to work in laboratory, hangar, and flight line environments.
- Ability to access instrumentation installed on aircraft, including climbing ladders, platforms, and confined spaces.
Benefits
- Catered lunches with rotating menu options
- Snacks and beverages including coffee and tea
- Health insurance
- Dental insurance
- Life insurance
- Unlimited vacation
- 401(k) with company match
- Professional development support
- Startup environment focused on collaboration and innovation
Additional Information
- Equal opportunity employer
- Employment contingent upon background and reference checks
- Applicants must be authorized to work in the United States without visa sponsorship now or in the future
- Employment eligibility verification required upon hire
- Merlin Labs does not accept unsolicited resumes from third parties
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On-site
Lansing, MI
🏢 Summary: Senior engineering role responsible for leading the full lifecycle of composite repair projects for ground test equipment, from damage evaluation and quoting to repair design and execution oversight. The position involves developing repair processes, work instructions, and tooling while collaborating with customers and production teams. Up to 50% travel is required to support repair activities on site. 🗂️ Requirements: STEM degree with 15+ years relevant experience or advanced STEM degree with 10+ years experience, 10+ years experience with composite manufacturing processes, Experience with fiber-reinforced polymer composites (fiberglass, aramid, carbon prepreg, wet layup, epoxy systems), Comprehensive knowledge of advanced composite and bonded structures, Experience with mechanical design (machining, joints, fasteners, welding) in aerospace, defense, automotive or similar industries, Experience designing tooling for repairs or production processes, Familiarity with Non-Destructive Testing (ultrasonic, eddy current, FPI, X-ray, optics), Experience with GD&T and tolerance determination, Ability to travel up to 50%, US Citizenship and valid passport or ability to obtain one 📃 Skills: Composites, Fiber-reinforced, Fiberglass, Aramid, Carbon, Prepreg, Wet-layup, Epoxy, Adhesives, NDT, Ultrasonic, Eddy-current, FPI, X-ray, GD&T, Machining, Welding, Creo, Windchill, NX, FiberSIM, TeamCenter, CAE 🏢 Description: Job Description: As a Ground Test Composites Repair Engineer, you will be responsible for leading the complete project lifecycle for repairs of ground test equipment: - Decomposing customer requirements - Quoting - Evaluating damage - Designing / developing repair process - Work instruction development - Oversight of repair process execution You will evaluate damage from normal operations and develop repairs to restore assemblies or components to original requirements. What You Will Do: - Evaluate damage to ground test equipment during normal use and develop repairs to restore parts to original / acceptable conditions - Engage with customers to scope and inspect damage conditions prior to quoting and part arrival on site - Develop project schedule and cost to support quoting repair jobs - Communicate and deliver technical presentations to internal and external customers - Develop repairs, work instructions, and identify materials to support repair jobs, including engagement with production personnel - Develop standard repair processes to simplify repair execution - Support production personnel in performing repairs in the facility and at customer locations - Travel up to 50% as required to support repair work - Review and disposition nonconforming material to technical requirements - Contribute to Cost of Poor-Quality initiatives and drive process improvements - Ensure compliance with established engineering methodologies - Apply engineering judgment, technical expertise, and data analysis to solve moderately complex tasks - Support program management by developing engineering project plans, work packages, milestones, and objectives - Mentor junior designers Qualifications You Must Have: - STEM University Degree with minimum 15 years relevant experience, or STEM Advanced Degree with minimum 10 years experience - Effective problem identification and solution skills - Strong project ownership and execution mindset - 10 years experience with composite manufacturing processes - Experience with fiber-reinforced polymer composites: fiberglass, aramid, carbon prepreg, wet layup, especially epoxy resin systems - Comprehensive experience in advanced composite and bonded structures (organic/polymer matrix composites, fiber reinforcement, manufacturing methods, adhesives, surface preparation) - Knowledge of composites and bonded structures applications for gas turbines or similar applications - Experience with mechanical design (machining, joints, fasteners, welding) in aerospace, defense, automotive, or similar industries - Experience designing tooling to support repairs or production processes - Familiarity with Non-Destructive Testing (NDT) techniques such as ultrasonic testing, eddy current, FPI, camera optics, X-ray - Experience with GD&T including determining tolerance requirements - Ability to travel up to 50% of the time - US Citizen Qualifications We Prefer: - Advanced Degree in Engineering - Experience with Computer Aided Design software: Creo / Windchill (preferred) or NX / FiberSIM / TeamCenter - Computer Aided Engineering software experience - Experience with design for manufacturing and assembly - Experience documenting repair validation, analysis, and research - Understanding of manufacturing cost and reproducibility - Familiarity with product development, reliability, and quality control principles - Experience with configuration management Drug Screening Requirement: - Successful completion of pre-employment drug screening required