Senior Mechanical Engineer- Quadcopter Systems

As a Senior Mechanical Engineer, you will own the end-to-end mechanical architecture of our flagship quadcopter platforms, from initial CAD concept and structural design to payload packaging, physical prototyping, and production release. You will lead the mechanical design of lightweight structures and subsystems in SolidWorks, integrate electrical components into custom airframe volumes, and perform hands-on lab validation including vibrational, thermal, and drop testing. You will also conduct structural and thermal simulations, collaborate with suppliers on DFM, and support assembly enablement to ensure high build quality and fast throughput.

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 optimize 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.
• 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.