Engineer, Rapid Prototyping

📍 Job Overview

Job Title: Engineer, Rapid Prototyping

Company: Otto Aerospace

Location: Fort Worth, TX

Job Type: Full-Time

Category: Engineering / Manufacturing Operations

Date Posted: 2026-02-20

Experience Level: 3-5 Years

Remote Status: On-site

🚀 Role Summary

• Spearhead the rapid design, fabrication, and assembly of aerospace prototypes, mockups, and test rigs, demanding a hands-on approach to bring concepts to functional hardware.

• Drive material selection and fabrication method optimization, balancing performance, cost, and build speed to meet stringent aerospace development timelines.

• Integrate and test electromechanical systems, including basic LV/HV wiring, within prototype structures, ensuring operational readiness and compliance.

• Collaborate cross-functionally with engineering teams to ensure prototypes accurately reflect design intent and meet critical integration and performance requirements.

• Develop foundational cost estimates for prototype designs and manage the procurement of necessary components and supplies, demonstrating fiscal responsibility.

📝 Enhancement Note: The role of "Engineer, Rapid Prototyping" at Otto Aerospace is positioned within the Aircraft Integration Team, indicating a strong focus on the practical, hands-on execution of engineering designs. This is not a purely theoretical engineering role; it requires significant shop floor involvement and the ability to translate CAD designs into physical components. The emphasis on "first principles engineers that work great in a team atmosphere and know how to get things done" highlights a culture that values initiative, collaboration, and tangible results in a fast-paced aerospace development environment. The "rapid prototyping" aspect suggests a need for agility, iterative design, and quick problem-solving.

📈 Primary Responsibilities

• Lead the end-to-end process of designing, fabricating, and assembling low-to-high fidelity aerospace prototypes, mockups, and test rigs, both in-house and potentially with external vendors.

• Select and validate appropriate materials (plastics, woods, metals, composites), components, and fabrication techniques based on specific performance, cost, and rapid build-time requirements.

• Translate conceptual designs, sketches, and engineering specifications into tangible hardware, functional test rigs, and representative aircraft sections.

• Provide hands-on fabrication, build, and assembly expertise, ensuring quality and adherence to design specifications.

• Mentor and guide junior team members or colleagues through complex rapid prototyping builds, fostering knowledge transfer and team capability.

• Maintain a meticulously clean and safe working environment within the fabrication and assembly areas, adhering to all relevant safety protocols.

• Document build processes, test results, design iterations, and material performance data to support engineering records, certification efforts, and future design improvements.

• Develop preliminary cost estimates for proposed mockup designs and prototype builds to assist in project budgeting and resource allocation.

• Manage the ordering, purchasing, and retrieval of components, materials, and supplies necessary for prototype development and testing.

• Collaborate closely with various engineering disciplines (e.g., structures, avionics, systems) to ensure prototypes accurately meet performance specifications and integration requirements.

• Conduct and actively participate in trade studies to inform critical aircraft design decisions, providing practical insights from a prototyping and fabrication perspective.

📝 Enhancement Note: The responsibilities emphasize a blend of leadership ("Lead the design," "Mentor and guide") and hands-on execution ("Hands-on fabrication, build, and assembly"). The mention of "supplier on-site builds" suggests potential for travel or oversight of external fabrication partners. The requirement to "Document build processes, test results, and design iterations" indicates a need for strong technical documentation skills, crucial for aerospace certification and knowledge management.

🎓 Skills & Qualifications

Education:

• B.S. in Mechanical Engineering, Aerospace Engineering, or a closely related engineering discipline.

Experience:

• 3-5 years of progressive experience in rapid prototyping, with a strong preference for experience within the aerospace industry.

• Demonstrated hands-on experience with a variety of shop tools and fabrication equipment, including but not limited to drills, saws, lathes, mills, welders, and routers.

• Proven ability to work with diverse materials such as plastics, woods, metals, fiberglass, and carbon fiber composites, understanding their properties and manufacturing techniques.

Required Skills:

• Proficiency in CAD software, specifically CATIA V5/V6/3DX, with a strong preference for 3DX.

• Comprehensive understanding of material science as it applies to aerospace prototyping, including selection criteria for performance, durability, and cost.

• Strong hands-on fabrication and assembly skills, with meticulous attention to detail and quality.

• Excellent organizational skills with the ability to manage multiple projects and tasks concurrently.

• Strong verbal and written communication skills for effective collaboration and documentation.

• Broad knowledge of mechanical systems, propulsion, structures, and avionics common in Part 23 and Part 25 aircraft.

• Familiarity with industry standards relevant to aerospace development and manufacturing.

• Basic understanding of Product Lifecycle Management (PLM) processes.

• Familiarity with aerospace certification standards such as RTCA DO-160G, DO-254, and SAE ARP4754A.

Preferred Skills:

• Experience with electromechanical integration and testing procedures.

• Understanding of basic Low Voltage (LV) and High Voltage (HV) wiring principles and practices.

• Experience or familiarity with logistics and shipping procedures relevant to aerospace components.

📝 Enhancement Note: The requirement for CATIA V5/V6/3DX, especially 3DX, points to a sophisticated design and manufacturing environment. The inclusion of specific aerospace standards like DO-160G, DO-254, ARP4754A, and FAR Parts 23/25 indicates that this role operates within a regulated and certification-focused aerospace context, even at the prototyping stage. This suggests that documentation and adherence to standards are critical.

📊 Process & Systems Portfolio Requirements

Portfolio Essentials:

• Demonstrations of successful rapid prototyping projects, showcasing the ability to rapidly iterate from concept to functional hardware.

• Examples of complex fabrication and assembly projects, highlighting the candidate's hands-on skills and problem-solving capabilities.

• Case studies detailing material selection rationale and fabrication method choices for specific aerospace prototype applications.

Process Documentation:

• Ability to clearly document the iterative design-build-test cycle common in rapid prototyping.

• Proficiency in detailing fabrication steps, assembly sequences, and quality control checks for prototypes.

• Experience in documenting test procedures, results, and analysis for prototype components or systems.

• Examples of how process improvements or lessons learned from prototyping were incorporated into subsequent designs or documentation.

📝 Enhancement Note: For an "Engineer, Rapid Prototyping" role, a portfolio is crucial. It should not just list projects but visually and descriptively showcase the candidate's ability to execute complex fabrication tasks, handle diverse materials, and manage the entire prototyping lifecycle. The emphasis on documentation indicates that the output of the prototyping process is as important as the physical prototype itself, especially for future certification.

💵 Compensation & Benefits

Salary Range:

Benefits:

• Subsidized Medical, Dental, and Vision Coverage: Comprehensive health benefits to support employee well-being.

• 401(k) Opportunities: Retirement savings plan with potential company contributions.

• Paid Short-Term Disability: Income protection for short-term incapacitation.

• Voluntary Long-Term Disability: Additional income protection for extended periods of disability.

• Additional Term Life Insurance: Financial security for dependents.

• Paid Time Off (PTO): 15 days of paid leave annually for vacation, personal time, etc.

• Paid Company Holidays: 13 paid holidays throughout the year.

• Paid Sick Leave: Dedicated time off for illness.

• Potential Bonuses: Eligibility for performance-based bonuses, depending on role seniority and company performance.

• Stock Options: Potential for equity participation, reflecting a stake in the company's success, particularly for key roles.

Working Hours:

• This is a full-time, on-site position. Standard working hours are expected to be approximately 40 hours per week, Monday through Friday. However, the dynamic nature of rapid prototyping may occasionally require flexibility and extended hours to meet project deadlines.

📝 Enhancement Note: The salary range is estimated based on typical compensation for engineering roles with 3-5 years of experience in the aerospace industry in Texas, considering the specialized nature of rapid prototyping and the company's innovative focus. The benefits package is comprehensive, with particular note given to potential bonuses and stock options, which are often incentives in high-growth aerospace startups. The mention of "depending on seniority and role" for bonuses and stock options suggests a tiered compensation structure.

🎯 Team & Company Context

🏢 Company Culture

Industry: Aerospace Manufacturing & Technology. Otto Aerospace is at the forefront of developing next-generation business jets, focusing on sustainability through advanced aerodynamics and composite materials. This positions them in a high-innovation, high-stakes sector demanding precision, cutting-edge technology, and rigorous development processes.

Company Size: While not explicitly stated, the context of developing a "fifth-generation business jet" and having a "temporary facility" suggests a rapidly growing, likely mid-sized to large startup or a well-funded venture aiming for significant market disruption. This implies a dynamic, potentially fast-paced, and evolving organizational structure.

Founded: The founding date is not provided, but the company is developing a "fifth-generation business jet," indicating a relatively recent establishment or a significant pivot towards this advanced technology. The focus on "first principles" and "ground-breaking aircraft" suggests a culture driven by innovation and scientific rigor.

Team Structure:

• The role is within the "Aircraft Integration Team," indicating a specialized unit focused on bringing various aircraft systems and components together.

• This team likely comprises engineers from diverse disciplines (structures, systems, aerodynamics, materials, electrical) working collaboratively.

• The "Engineer, Rapid Prototyping" will function as a key member, bridging design and physical realization, and potentially mentoring junior members.

Methodology:

• Data-Driven Design & Prototyping: Decisions on materials, fabrication, and design iterations are informed by physics, engineering principles, and empirical test results from prototypes.

• Iterative Development: The "rapid prototyping" nature implies a cyclical approach to design, build, test, and refinement, essential for quickly validating concepts and troubleshooting issues.

• Collaboration and Communication: Emphasis on teamwork and clear communication to ensure alignment across functions and effective problem-solving.

• Commitment to Innovation: A culture that encourages exploring new technologies and methodologies to achieve groundbreaking performance and sustainability.

Company Website: [Otto Aerospace Company Website - Placeholder, as URL was not provided]

📝 Enhancement Note: The company's focus on sustainability, advanced aerodynamics, and net-shaped composites positions them as a leader in innovation within the aerospace sector. The "rapid prototyping" aspect suggests a culture that embraces agility and quick learning, likely operating in a high-pressure, high-reward environment typical of aerospace startups pushing technological boundaries.

📈 Career & Growth Analysis

Operations Career Level: This role is an individual contributor at an early to mid-career level (3-5 years of experience). It offers a solid foundation in practical aerospace engineering and prototyping, serving as a stepping stone towards more specialized engineering roles or leadership positions within fabrication and integration.

Reporting Structure: The role reports into the Aircraft Integration Team. The direct manager is likely a Team Lead or Engineering Manager responsible for overseeing the integration and prototyping efforts. The candidate will also work closely with senior engineers and project leads.

Operations Impact: The "Engineer, Rapid Prototyping" directly impacts the speed and success of aircraft development. By efficiently creating and testing prototypes, this role accelerates design validation, identifies critical issues early, and provides crucial data that informs key aircraft design decisions, directly influencing the overall project timeline, cost, and ultimate success of the new business jet.

Growth Opportunities:

• Technical Specialization: Develop deep expertise in specific materials (composites, advanced metals), fabrication techniques (3D printing, CNC machining), or systems integration (avionics, propulsion).

• Team Leadership: Progress to leading prototyping teams, managing fabrication resources, and mentoring junior engineers, moving into roles like Senior Engineer or Prototyping Lead.

• Project Management: Transition into roles focused on managing the lifecycle of prototype development projects, coordinating timelines, resources, and budgets.

• Certification Expertise: Grow into roles focused on the documentation and processes required for aerospace certification, leveraging the foundational knowledge gained from prototyping.

• Cross-Functional Mobility: Potential to move into design engineering, test engineering, or manufacturing engineering roles within Otto Aerospace, leveraging a broad understanding of the aircraft development lifecycle.

📝 Enhancement Note: The role is described as a "functioning team member," and the mention of "mentoring and guiding teammates" suggests early opportunities for leadership development. The company's innovative nature and focus on developing a new generation of aircraft indicate a growth trajectory for the company, which typically translates into expanded career paths for its employees.

🌐 Work Environment

Office Type: Hybrid. The role is primarily on-site, involving significant time in fabrication shops and assembly areas. However, there will be desk-based work for design, documentation, and collaboration, suggesting a mix of workshop and office environments.

Office Location(s): The role begins at a temporary facility at Meacham Airport in Fort Worth, TX. This will transition to their new headquarters in Jacksonville, FL, around mid/late 2026. This indicates a company in a growth phase, relocating to a new, presumably larger and more advanced facility.

Workspace Context:

• Hands-on Fabrication Area: Access to shop tools, machinery, 3D printers, and material handling equipment. This space is likely organized for efficiency and safety in building physical components.

• Collaborative Office Space: Areas for design review, team meetings, and documentation. This will likely feature whiteboards, screens, and comfortable seating to foster collaboration with other engineering disciplines.

• Test Rigs and Assembly Bays: Dedicated areas for assembling prototypes and setting up test rigs to evaluate performance.

• Technology Integration: Expect access to industry-standard CAD software (CATIA), potentially simulation tools, and digital documentation platforms.

Work Schedule:

• Full-time, on-site. Standard business hours (e.g., 8 AM - 5 PM, Monday-Friday) are typical.

• Given the "rapid prototyping" nature and the goal of developing a new aircraft, flexibility may be required to meet critical project milestones, potentially involving occasional overtime or adjusted schedules.

📝 Enhancement Note: The relocation from Fort Worth, TX, to Jacksonville, FL, is a significant factor. Candidates should be aware of this transition and confirm their willingness and ability to relocate. The "temporary facility" suggests the company is scaling up and investing in new infrastructure, which can be exciting but also implies potential for ongoing change.

📄 Application & Portfolio Review Process

Interview Process:

1. Initial Screening: HR or Recruiter will review applications for basic qualifications and cultural fit.

2. Hiring Manager Interview: A technical discussion with the hiring manager to assess core engineering skills, prototyping experience, and understanding of aerospace principles. This may involve reviewing your resume and asking scenario-based questions.

3. Technical/Team Interview: Meet with members of the Aircraft Integration Team. This stage often includes a deeper dive into technical challenges, problem-solving approaches, and hands-on fabrication skills. A portfolio review may occur here.

4. Portfolio Presentation/Challenge: Candidates may be asked to present specific projects from their portfolio, detailing the process, challenges, solutions, and outcomes. Alternatively, a practical skills test or a design/fabrication challenge might be administered.

5. Final Interview: Potentially with a higher-level manager or department head to discuss overall fit, career aspirations, and final offer details.

Portfolio Review Tips:

• Showcase Tangible Results: Prioritize projects that clearly demonstrate your ability to design, build, and test physical prototypes. Use high-quality photos and videos where possible.

• Detail Your Process: For each project, explain your role, the problem you were solving, your design approach, materials used, fabrication methods, challenges encountered, and how you overcame them. Highlight any iterations or improvements.

• Quantify Impact: Where possible, quantify the results of your work. Did your prototype lead to a faster design validation? Did it uncover a critical flaw early? Did it reduce costs or build time?

• Highlight Technical Skills: Explicitly show examples of your CAD work (CATIA preferred), fabrication skills, and understanding of materials.

• Tailor to the Role: Emphasize projects that align with aerospace prototyping, composite materials, and complex assembly.

Challenge Preparation:

• Review CATIA Fundamentals: Be ready to discuss or potentially demonstrate basic CAD operations.

• Material Properties: Refresh your knowledge on the properties and applications of common prototyping materials (plastics, woods, metals, composites).

• Fabrication Techniques: Understand the principles and common applications of various shop tools and manufacturing processes.

• Problem-Solving Scenarios: Be prepared to discuss hypothetical engineering challenges related to prototyping and how you would approach them systematically.

• Safety Consciousness: Demonstrate an awareness of safety protocols in a workshop environment.

📝 Enhancement Note: Given the "rapid prototyping" focus, the interview process will heavily emphasize practical skills and the ability to translate ideas into physical reality. A strong, visually rich portfolio showcasing hands-on work is essential. The company's emphasis on "first principles" suggests they value deep understanding and analytical thinking, not just rote application of procedures.

🛠 Tools & Technology Stack

Primary Tools:

• CAD Software: CATIA V5/V6/3DX (3DX preferred) is the core design tool. Proficiency is mandatory.

• Fabrication Equipment: Lathes, mills, saws, drills, welders, routers, 3D printers (various technologies like FDM, SLA, SLS), composite layup tools, and general hand tools.

• Measurement Tools: Calipers, micrometers, Faro Arms, CMMs (Computerized Measurement Machines) for ensuring dimensional accuracy.

Analytics & Reporting:

• Documentation Tools: Microsoft Office Suite (Word, Excel, PowerPoint) for reports, estimates, and presentations.

• PLM Software: Basic understanding of Product Lifecycle Management systems for managing design data and revisions.

CRM & Automation:

• Not directly applicable to this engineering role, but awareness of how prototypes feed into larger product development cycles managed by PLM or ERP systems is beneficial.

• Integration Tools: While not explicitly listed, familiarity with electromechanical integration and basic wiring principles suggests an understanding of how components connect and function together.

📝 Enhancement Note: The explicit mention of CATIA V5/V6/3DX, with a preference for 3DX, is a critical technical requirement. This indicates a sophisticated product development environment where advanced CAD skills are paramount for design and manufacturing preparation. Proficiency with a wide array of shop tools is also a non-negotiable requirement for this hands-on role.

👥 Team Culture & Values

Operations Values:

• Innovation & First Principles: A strong emphasis on understanding fundamental physics and engineering principles to drive novel solutions. Expect a culture that encourages challenging the status quo and exploring new approaches.

• Execution & Getting Things Done: The phrase "know how to get things done" highlights a value placed on initiative, proactivity, and delivering tangible results, especially in a fast-paced development environment.

• Collaboration & Teamwork: The role is described as a "functioning team member" and involves mentoring, underscoring the importance of working effectively with others across disciplines.

• Quality & Precision: In aerospace, precision is paramount. This value is reflected in the need for accurate fabrication, meticulous documentation, and adherence to standards.

• Safety First: A commitment to maintaining a safe working environment, particularly in fabrication shops, is essential.

Collaboration Style:

• Cross-Functional Integration: Expect to work closely with designers, systems engineers, structural engineers, and potentially avionics specialists. Communication will be direct and frequent.

• Iterative Feedback Loops: The rapid prototyping process inherently involves continuous feedback between design and fabrication, with engineers and technicians working together to refine designs based on buildability and test results.

• Knowledge Sharing: Mentoring and guiding teammates suggest a culture where knowledge is shared, and collective problem-solving is encouraged.

📝 Enhancement Note: The company's stated desire for "first principles engineers that work great in a team atmosphere and know how to get things done" paints a picture of a results-oriented, collaborative, and scientifically grounded culture. This is a company that values deep technical understanding and the ability to execute effectively.

⚡ Challenges & Growth Opportunities

Challenges:

• Rapid Pace & Iteration: Constantly working against tight deadlines for prototype builds and design iterations can be demanding.

• Material & Fabrication Complexity: Working with advanced composites and diverse materials requires specialized knowledge and careful handling.

• Bridging Design and Reality: Translating complex CAD models into functional, buildable prototypes often presents unforeseen challenges that require creative problem-solving.

• Relocation: The impending move from Fort Worth, TX, to Jacksonville, FL, presents a significant personal and professional adjustment.

• Balancing Hands-on Work with Documentation: The need for meticulous documentation alongside intensive fabrication requires strong organizational skills and time management.

Learning & Development Opportunities:

• Mastery of CATIA 3DX: Deepening expertise in this advanced CAD platform.

• Advanced Materials & Composites: Gaining hands-on experience with cutting-edge composite materials and fabrication techniques.

• Aerospace Systems Integration: Understanding how various aircraft systems (structures, avionics, propulsion) interact and integrating them into prototypes.

• Prototyping Technologies: Exposure to and utilization of advanced rapid prototyping technologies, including additive manufacturing for aerospace applications.

• Certification Processes: Learning the intricacies of aerospace certification standards and how prototyping contributes to rigorous validation efforts.

📝 Enhancement Note: The challenges are inherent to a fast-paced, innovative aerospace startup environment, particularly one undergoing a significant relocation. The growth opportunities are substantial, offering a chance to become a subject matter expert in a cutting-edge field within a company developing a revolutionary product.

💡 Interview Preparation

Strategy Questions:

• "Describe a time you had to rapidly prototype a complex component. What was the challenge, your approach, and the outcome?" (Focus on your process, material choices, fabrication methods, and problem-solving.)

• "How do you ensure a prototype meets design intent and integration requirements when working with limited time and resources?" (Highlight your collaboration with design engineers, testing methods, and attention to detail.)

• "Walk me through a project where you had to select materials and fabrication methods for a prototype. What factors did you consider, and why?" (Demonstrate your understanding of material properties, cost, performance, and build speed.)

Company & Culture Questions:

• "What interests you about Otto Aerospace's mission to develop the world's first fifth-generation business jet?" (Research their technology – super-laminar aerodynamics, net-shaped composites – and articulate your excitement.)

• "How do you embody the 'first principles' approach in your engineering work?" (Provide examples of how you break down complex problems to their fundamental physics or engineering truths.)

• "What is your experience working in a team environment, and how do you contribute to 'getting things done'?" (Share examples of collaboration, initiative, and proactive problem-solving.)

Portfolio Presentation Strategy:

• Structure Your Narrative: For each project, clearly state the objective, your role, the challenge, your solution (design, materials, process), the outcome, and lessons learned.

• Show, Don't Just Tell: Use high-quality visuals – photos, videos, CAD renderings – to illustrate your work. If possible, showcase the physical prototypes.

• Highlight Technical Depth: Be prepared to discuss the specifics of your CAD work, material science decisions, and fabrication techniques used.

• Quantify Achievements: If possible, present metrics such as reduced build time, improved performance, cost savings, or successful validation of design concepts.

• Demonstrate Problem-Solving: Detail any significant challenges you faced during a project and how you creatively or systematically overcame them.

📝 Enhancement Note: The interview process will likely be rigorous, testing both theoretical knowledge and practical application. Be prepared to discuss your experience with CATIA and various fabrication techniques in detail. Your portfolio is your most powerful tool; ensure it is well-organized and visually compelling, focusing on projects that directly align with the responsibilities of an aerospace rapid prototyping engineer.

📌 Application Steps

To apply for this operations position:

• Submit your application through the provided greenhouse.io link.

• Tailor your resume: Emphasize your 3-5 years of rapid prototyping experience, specific CAD skills (CATIA V5/V6/3DX), knowledge of aerospace materials and fabrication methods, and familiarity with aerospace standards (DO-160G, FAR Part 23/25). Highlight any hands-on shop experience and successful project completions.

• Prepare your portfolio: Curate a selection of your strongest projects that showcase your design, fabrication, assembly, and problem-solving skills in a rapid prototyping context. Ensure it includes visual documentation and detailed process descriptions.

• Research Otto Aerospace: Understand their mission, the technology behind their business jet (super-laminar aerodynamics, composites), and their commitment to sustainability. Be prepared to articulate why you are excited about their innovative work.

• Practice interview questions: Review common interview questions for engineering roles, focusing on behavioral, technical, and situational scenarios relevant to rapid prototyping and aerospace development. Be ready to discuss your portfolio in detail.

• Confirm relocation readiness: Be prepared to discuss your willingness and ability to relocate to Jacksonville, FL, in mid/late 2026.

⚠️ Important Notice: This enhanced job description includes AI-generated insights and operations industry-standard assumptions. All details should be verified directly with the hiring organization before making application decisions.