Firestorm is seeking a Principal Airframe Design Engineer to lead the design and build of critical flight structures and mechanisms for next-generation UAV systems. You will own the hardware product lifecycle of the airframe, from concept through production, and collaborate cross-functionally with electrical, manufacturing, and flight-test teams. As an individual contributor, you will influence technical direction, mentor junior engineers, and drive engineering best practices across projects.

Responsibilities

Lead mechanical design efforts for key UAV subsystems across the entire product lifecycle: concept, prototyping, testing, production, and field support.
Develop innovative, manufacturable airframe designs optimized for UAV flight performance under varying operational conditions, ensuring structural, dynamic, thermal and functional requirements are met through rigorous analysis and validation.
Analyze initial aerostructure designs against preliminary mass properties targets and strength and stiffness requirements.
Create and maintain high-quality 3D CAD models, detailed engineering drawings, and manufacturing documentation using SolidWorks, emphasizing GD&T principles to ensure precision and manufacturability.
Lead the structural mechanical design of aircraft primary and secondary structures in the airframe, from initial concept through production.
Develop and champion innovative structural solutions to optimize weight, cost, and performance.
Develop structural requirements, specifications, and test plans (DVP&R).
Review of static & dynamic load inputs, material properties and test results.
Lead and oversee structural testing, expertly analyze test data, and take ownership of generating detailed test reports.
Proactively investigate and resolve complex structural issues that arise during development and providing robust design solutions.
Drive high-cadence iterative design and analysis cycles, supporting rapid prototyping and cross-functional design reviews to incorporate test feedback promptly and continuously improve hardware through agile development processes.
Collaborate cross-functionally with electrical engineers, flight-test engineers, and manufacturing teams to integrate complex mechanical and electromechanical systems, including servos, pumps, sensors, cameras, PCBAs, wiring harnesses, and connectors.
Own technical reviews and contribute to design and analysis decisions, ensuring robust engineering practices and adherence to program requirements.
Support rapid prototyping efforts with hands-on experience building functional prototypes in a shop environment, iterating designs based on real-world results and test data.
Troubleshoot mechanical and electromechanical issues through root cause analysis and implement effective corrective actions.
Contribute to configuration management and documentation control, maintaining clear versioning of CAD files, assemblies, and design revisions.
Build and maintain engineering rigor by contributing to the development of company-wide best practices, including CAD standards, documentation protocols, and hardware management processes. Write detailed build documentation and collaborate hands-on with technicians during hardware integration and assembly.
Cultivate a high-performing design culture by mentoring junior and mid-level engineers, leading technical design reviews, and formalizing company-wide standards for airframe architecture.

Requirements

Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, or a related discipline.
10+ years of mechanical design experience, working directly with aircraft design.
Proven track record of taking complex mechanical assemblies from concept to production.
Strong foundation in mechanical engineering fundamentals; structures, fluid systems, thermal management, and mechanisms.
Hands-on design engineering experience, with proven application of design-for-manufacturability (DFM) principles.
Demonstrated ability to perform structural modeling and analysis of mechanical components and assemblies.
Proficiency in first-order structural analysis and hand calculations, including free body diagrams, statics, and mechanics of materials.
Experience in SolidWorks, including surfacing, top-down design, and advanced modeling techniques, plus strong knowledge of GD&T principles.
Experience integrating mechanical designs with electrical systems, including PCBAs, wiring harnesses, and electromechanical components such as servos and sensors.
Direct application of DFM and designing for additive, traditional, and composite manufacturing methods, including tooling and fixturing for composite assemblies.
Demonstrated technical leadership, with a proven track record of mentoring junior and mid-level engineers, conducting rigorous design reviews, and elevating the technical standards of a growing engineering organization.
U.S. Citizenship and ability to obtain and maintain a U.S. Government security clearance.

Nice to have

12+ years of professional mechanical design experience, working directly with aircraft structural design.
Background supporting the full hardware development lifecycle, including design, prototyping, testing, and production.
Demonstrated skill in correlating analytical results with physical test data and applying findings to improve design performance.
Familiarity with configuration management, version control practices for CAD, and engineering documentation control.
Familiarity with designing injection-molded components or polymer-based additive manufacturing techniques.

Benefits

We offer comprehensive medical, dental, and visions plans
401(k) Retirement Savings Plan to invest in your long-term retirement goals
Equity grants for new hires
Unlimited PTO
Extremely generous company holiday calendar, including a holiday hiatus in November, & December.
Generous Parental Leave
Lifestyle Spending Account
FSA
DCFSA
HSA
Hospital Indemnity insurance
Critical Illness insurance
Accident insurance
Basic Life/AD&D, short-term and long-term disability insurance, 100% covered by Firestorm. Plus, the option to purchase additional life insurance for you and your family.
Mental Health Resources: We provide free mental health resources 24/7 including therapy and more. Additional work-life services, such as free legal and financial support, are available to you as well.