Freelance Additive Manufacturing Engineer Jobs in Portland, OR

IRPI is pioneering the hardware that sustains life and enables exploration beyond Earth.
We design and build flight systems for spacecraft, habitats, and suits, advancing systems that manage air, water, waste, and thermal control for human missions. Our portfolio spans CO₂ removal and air revitalization, hydroponics, biological sample processing, waste management, and fire safety, as well as condensing heat exchangers, propellant management devices, lunar lander components, and advanced suit subsystems.
What makes IRPI unique is how we integrate research, design, and fluid-thermal engineering to produce hardware that performs in the most demanding environments. From early-stage concepts to flight-qualified systems, we transform ideas into tested, mission-ready technology that expands the boundaries of human presence in space.
Your Mission
As a Senior Mechanical Engineer, you'll be a technical anchor on active NASA and commercial space programs - the person others turn to when a problem is hard, a design needs defending, or a test result doesn't make sense. You'll bring deep expertise across mechanical, thermal, and fluid systems, and apply it end-to-end: from concept through analysis, prototyping, test, and flight integration.
This is not a narrow specialist role, and it demands range in altitude as much as in discipline. You'll get hands-on in the lab when a build stalls or a test result doesn't add up - then step back to weigh that detail against program priorities, schedule, and risk. We need someone who can dive into the weeds without getting lost in them: the details matter, but so does knowing which ones matter most.
Just as important, you'll multiply the team around you. You'll work closely with principal engineers and program leads, and serve as a key technical resource for mid-level and early-career engineers - reviewing their work, sharing your reasoning, and helping them build the judgment that only comes from experience.
Strong candidates at this level are recognized for the quality of their engineering judgment, not just their output.
This position requires access to export-controlled technology. Only U.S. citizens or nationals are eligible.
Key Responsibilities

• Own the design, analysis, and test of complex mechanical, thermal, and fluid subsystems across multiple active projects.
• Mentor mid-level and early-career engineers: review their designs, analyses, and test plans; give direct, constructive feedback; and help them develop sound engineering judgment.
• Balance hands-on problem-solving with program-level judgment - know when a detail warrants a deep dive and when it's good enough to move forward.

• Lead trade studies, develop design concepts, and drive technical decisions through PDR, CDR, and into flight.

• Produce and review detailed SolidWorks models, assemblies, and drawings; enforce configuration control discipline across the team.

• Author and maintain bills of materials for prototype and flight builds; coordinate with suppliers and fabricators.

• Plan and lead test campaigns: design test setups, write procedures, execute tests, and deliver clear engineering conclusions from the data.

• Diagnose and resolve complex design, analysis, or test anomalies - and document your reasoning rigorously.

• Serve as a technical point of contact with NASA and commercial partners during reviews and integration activities.
• Contribute to IRPI's culture of continuous improvement, accountability, and technical excellence.

Requirements
Minimum Qualifications

• B.S. or M.S. in Mechanical, Aerospace, or related engineering field.
• 7+ years of experience designing, analyzing, and testing mechanical and thermal-fluid systems; M.S. counts as 1 year toward this requirement.
• Demonstrated technical depth: you are the person who has solved hard problems, not just contributed to the team that did.
• Proven end-to-end ownership of subsystems through design, analysis, test, and - ideally - flight or qualification.
• Expert-level proficiency in SolidWorks or equivalent CAD, including manufacturing drawings, GD&T, and tolerance analysis.
• Hands-on experience with prototyping, machining, or additive manufacturing; you build and test, not just simulate.
• Strong command of test instrumentation, data acquisition, and analysis (Excel, MATLAB, or Python).
• Excellent written and verbal communication; able to present technical conclusions clearly to internal and external stakeholders.
• U.S. citizenship or nationality (required for export-controlled work).

Nice to Have

• Experience at a small space company, startup, or small-team R&D environment.
• Direct experience with NASA program lifecycles, formal design reviews (PDR/CDR), or flight qualification processes.
• Familiarity with aerospace standards (NASA-STD-5001, MIL-STD-1540, or similar).
• Track record of mentoring engineers or leading small technical efforts.

Benefits
Compensation & Perks

• Medical insurance
• Dental insurance
• 401(k) with employer contribution
• Paid vacation
• Paid sick leave
• Paid holidays
• Paid parental leave & flexibility
• Annual performance bonuses
• Salary: $130,000 - $165,000, based on experience and degree

How to Apply
Be sure to answer all application questions fully and thoughtfully. Our hiring team reviews every application and may also consider you for other positions that align with your skills and interests.
If you have a thesis, dissertation, technical presentation, or published work, please include it. A cover letter is optional but encouraged if it provides context not captured in your resume, particularly around programs you've worked on and the nature of your technical contributions.
Equal Opportunity Employer
IRPI is an Equal Opportunity Employer. We evaluate qualified applicants without regard to race, color, religion, sex, gender identity or expression, sexual orientation, national origin, age, disability, veteran status, marital status, or any other legally protected category.