Senior Staff Airframe Design Engineer
$145,000–$175,000 year
On-siteSan Diego, California, United States
Job Summary
Lead mechanical design efforts for key UAV subsystems across the entire product lifecycle, from concept through production and field support. Develop innovative, manufacturable airframe designs optimized for flight performance, ensuring structural, dynamic, thermal, and functional requirements are met through rigorous analysis and validation. Create and maintain high-quality 3D CAD models, detailed engineering drawings, and manufacturing documentation using SolidWorks, emphasizing GD&T principles. Lead the structural mechanical design of aircraft primary and secondary structures, develop structural requirements and test plans, and oversee structural testing while analyzing data to generate detailed reports. Proactively investigate complex structural issues, drive iterative design cycles, and collaborate cross-functionally with electrical, manufacturing, and flight-test teams to integrate electromechanical systems. Own technical reviews, contribute to design decisions, and mentor junior engineers to cultivate a high-performing design culture.
Required Qualifications
- Bachelor's degree in Mechanical Engineering, Aerospace Engineering, or a related discipline
- 7+ 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
- Must be able to lift up to 30 lbs
- Willingness to travel up to 10% domestically for testing and demonstrations
Desired Qualifications
- 7+ 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
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