Mechanical Engineer - UAS

The Mechanical Engineer will design, fabricate, test, and iterate on complete mechanical systems for the Blackfoot tactical FPV drone platform, including airframes, propulsion integration, payload bays, and structural hardware. The role emphasizes hands-on development, rapid iteration, and system-level ownership across the full hardware lifecycle, working closely with flight operations to close the loop between design intent and real-world performance. The engineer will support mechanical design, perform structural analysis, integrate propulsion components, and drive designs from prototype through production.

Responsibilities

• Support mechanical design across airframe, motor mounts, payload bays, & landing systems
• Design and fabricate multi-component assemblies for high-performance drone platforms
• Perform structural and FEA analysis to validate designs under flight, loads, and crash
• Select and specify materials including CFRP composites, aluminum alloys, and engineering plastics for weight-critical applications
• Integrate propulsion system components including motor mounts, ESC thermal management, and propeller clearance envelopes
• Conduct mass properties analysis (CG, MOI) and coordinate with flight systems team to maintain acceptable flight dynamics
• Design vibration isolation solutions to protect sensitive electronics (IMU, cameras, RF systems) on propeller-driven airframes
• Develop and maintain technical drawings with GD&T callouts per ASME Y14.5 standards
• Build, test, and iterate hardware rapidly using real-world feedback from flight operations
• Support MIL-STD-810 environmental testing (shock, vibration, temperature, humidity) and implement design improvements
• Coordinate mechanical/electrical interface design including wiring harness routing, connector placement, and PCB mounting provisions
• Drive designs from prototype through production (DFM/DFA, BOM, & build documentation)

Requirements

• 3 years of hands-on mechanical engineering experience
• Proven experience designing and fabricating real hardware systems
• Strong CAD proficiency (SolidWorks preferred; CATIA, Fusion 360, or NX accepted)
• Demonstrated FEA experience (SolidWorks Simulation, ANSYS, or Abaqus)
• Working knowledge of GD&T per ASME Y14.5
• Experience with lightweight structural materials including CFRP composites or aluminum alloys
• Familiarity with DFM/DFA and hands-on prototype fabrication (CNC machining, FDM, SLA)
• Understanding of rotating propulsion system mechanics, vibration, and dynamic loading
• Ability to work independently and take ownership of ambiguous design problems

Nice to have

• Hands-on experience building, repairing, or flying FPV or tactical UAS platforms
• Familiarity with MIL-STD-810 test methods and environmental qualification requirements
• Experience with mass properties management and CG/MOI analysis for UAS platforms
• Knowledge of battery mechanical integration and thermal management in UAS airframes
• Experience coordinating with external machine shops or composite fabricators
• SolidWorks CSWA or CSWP certification
• Familiarity with payload integration for ISR or EW systems on tactical UxS
• Experience working in fast-paced R&D or defense environments