The Senior Aero-Mechanical Engineer leads the design, development, and validation of complex mechanical systems and subsystems for uncrewed aerial systems (UAS). They independently own major subsystem designs, balancing performance, reliability, and manufacturability, and contribute to the broader engineering architecture through technical review and mentorship. The role involves hands-on leadership during prototype builds, test campaigns, and production transitions, driving technical excellence and process improvements across multiple programs.

Responsibilities

Lead the design, modeling, and analysis of major mechanical and structural subsystems for UAS.
Perform and review tolerance analysis, structural analysis (FEA), and materials selection.
Oversee design documentation, drawing release, and configuration management activities.
Coordinate design integration across disciplines—mechanical, electrical, and software.
Guide prototype builds, resolving issues related to manufacturability, fit, and performance.
Develop and execute test plans to validate structural integrity and system performance.
Lead and participate in design reviews (CoDR, PDR, CDR) and incorporate feedback into designs.
Support production readiness and quality verification for new and existing products.
Mentor junior engineers and CAD specialists, promoting technical best practices and efficient workflows.
Contribute to continuous improvement initiatives in design standards, configuration management, and documentation processes.

Requirements

Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, or a related field required.
4–7 years of relevant experience in mechanical or aerospace engineering, with demonstrated ownership of major subsystems or assemblies.
Proven experience developing products for aerospace, defense, or similarly regulated environments.
Experience supporting prototype, production, and test activities in a hands-on capacity.
Advanced proficiency with CAD modeling and drafting (SolidWorks preferred).
Deep understanding of GD&T, mechanical drawing standards, and documentation control.
Working knowledge of materials, composites, machined parts, and structural integration.
Experience performing FEA and interpreting results for design optimization.
Familiarity with PDM/PLM systems (e.g., SolidWorks PDM, Windchill).
Strong technical leadership and decision-making skills.
Excellent communication and collaboration across multi-disciplinary teams.
Analytical mindset with strong problem-solving and root-cause analysis capabilities.
Organized and detail-oriented with experience managing multiple design tasks simultaneously.
Ability to mentor others and uphold engineering rigor and design quality.

Nice to have

Master’s degree in Mechanical or Aerospace Engineering.
6–8 years of experience designing mechanical systems for UAS or defense applications.
Experience leading subsystem integration efforts and participating in flight or environmental testing.
Experience with advanced analysis tools (FEA, CFD, or fatigue analysis).
Familiarity with composite layup design, bonded structures, or lightweight mechanisms.
Experience developing and reviewing engineering standards or process documentation.
Familiarity with systems engineering practices and requirements traceability.
Strong leadership presence with the ability to influence technical direction.
Ability to synthesize feedback from multiple stakeholders into actionable design decisions.
Continuous improvement mindset, with a focus on efficiency and repeatable design excellence.
Comfort operating in fast-paced environments with evolving program requirements.

Benefits

Matching 401(k)
Paid PTO
Paid holidays
Medical, vision, and dental insurance
Group Short-Term & Long-Term Disability
HSA and FSA Options
Critical Care Plan
Accident Care Plan
Employee Stock Purchase Plan