Senior Mechanical Engineer – Quadcopter Systems

This Senior Mechanical Engineer role involves owning the end-to-end mechanical architecture of Harmattan AI's flagship quadcopter platforms. You will lead design from CAD concept through structural analysis, prototyping, and production release, working hands-on with SolidWorks and lab validation. The role requires close collaboration with cross-functional teams to integrate electrical components and optimize designs for manufacturing.

Responsibilities

• Quadcopter & Subsystem Architecture: Lead the mechanical design and modeling of lightweight quadcopter structures, fuselages, chassis, motor mounts, and quick-release mechanisms in SolidWorks from concept to production.
• Electromechanical Packaging: Lead spatial layouts and enclosure design to integrate electrical components (PCBs, wire harnesses, power distribution, motors, and sensors) tightly into custom airframe volumes.
• Rapid Prototyping & Physical Testing: Build functional prototypes and execute hands-on lab validation—including vibrational testing, modal analysis, thermal chamber runs, drop testing, and assisting with flight tests.
• Simulation & Thermal Analysis: Perform structural (FEA), modal, and thermal simulations alongside tolerance stack-up analyses to ensure designs withstand extreme defense operational environments.
• DFM & Production Documentation: Partner with Industrialisation, Procurement, and suppliers to optimise parts for plastic injection molding, CNC machining, sheet metal, and additive manufacturing.
• Assembly Enablement: Support Industrialisation engineers in defining assembly sequences, designing build jigs and fixtures, and training production operators to ensure high build quality and fast throughput.

Requirements

• Background: M.Sc. or B.Sc. (FH / HES / University of Applied Sciences) in Mechanical Engineering or a related technical field.
• Experience:
• 4+ years of hardcore, hands-on UAV design and development experience (demonstrated track record with physical drone airframes, multirotors, or flight hardware), OR
• 6+ years of overall mechanical engineering experience in complex Robotics, Autonomous Systems, or high-density Electromechanical hardware.
• End-to-End Ownership: Proven track record taking complex electromechanical assemblies from CAD concepts through functional prototypes to finished, physical production hardware.
• DFM Grounding: Practical design experience for plastic injection molding, CNC machining, sheet metal, and 3D printing, with direct supplier collaboration experience.
• Applied Physics & Problem Solving: Demonstrated skill in managing real-world physical constraints—including structural rigidity, heat dissipation, and vibration isolation.
• High Ownership & Drive: Proactive, responsive, and collaborative mindset—someone who takes full responsibility for their work and actively unblocks themselves under tight deadlines.

Benefits

• Complete System Ownership: Own the complete mechanical architecture of flagship quadcopter platforms rather than being siloed on a single bracket or cover.
• Unmatched Execution Speed: Move from CAD design to physical shop-floor testing in days, backed by strong resources and quick decision-making.
• Direct Mission Impact: Design and build hardware that actively deploys with allied forces to solve critical defense challenges.
• Cross-Functional Mastery: Work side-by-side with Electrical, Aerodynamics, Gimbal, and Production teams with complete visibility over how hardware moves from CAD to active flight.