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Firestorm · 18 hours ago

Senior Mechanical Design Engineer

San Diego, CA

Full-time

Onsite

Senior Level, Lead/Staff

$136K/yr - $178K/yr

8+ years exp

Firestorm is a VC-backed company aiming to revolutionize defense solutions with innovative technologies. They are seeking a Senior Mechanical Design Engineer to lead the design and structural analysis of UAV systems, overseeing the hardware product lifecycle and ensuring high-performance designs that meet operational requirements.

AerospaceArtificial Intelligence (AI)Drones

No H1B

U.S. Citizen Only

Responsibilities

Lead mechanical design and structural analysis efforts for key UAV subsystems across the entire product lifecycle: concept, prototyping, testing, production, and field support

Develop innovative, manufacturable airframe designs optimized for UAV flight performance under varying operational conditions, ensuring structural, dynamic, thermal and functional requirements are met through rigorous analysis and validation

Analyze initial aerostructure designs against preliminary mass properties targets and strength and stiffness requirements

Create and maintain high-quality 3D CAD models, detailed engineering drawings, and manufacturing documentation using SolidWorks, emphasizing GD&T principles to ensure precision and manufacturability

Lead the structural mechanical design of aircraft primary and secondary structures in the airframe, from initial concept through production

Develop and champion innovative structural solutions to optimize weight, cost, and performance, often taking the lead on these efforts

Develop structural requirements, specifications, and test plans (DVP&R) with minimal guidance

Review of static & dynamic load inputs, material properties and test results

Independently perform analyses using FEA and hand calculations to predict performance under various loading conditions (static, dynamic, fatigue, etc.)

Lead and oversee structural testing, expertly analyze test data, and take ownership of generating detailed test reports

Proactively investigate and resolve complex structural issues that arise during development and providing robust design solutions

Contribute to the development and improvement of structural analysis methodologies and best practices within the team

Drive high-cadence iterative design and analysis cycles, supporting rapid prototyping and cross-functional design reviews to incorporate test feedback promptly and continuously improve hardware through agile development processes

Collaborate cross-functionally with electrical engineers, flight-test engineers, and manufacturing teams to integrate complex mechanical and electromechanical systems, including servos, pumps, sensors, cameras, PCBAs, wiring harnesses, and connectors

Support technical reviews and contribute to design and analysis decisions, ensuring robust engineering practices and adherence to program requirements

Support rapid prototyping efforts with hands-on experience building functional prototypes in a shop environment, iterating designs based on real-world results and test data

Troubleshoot mechanical and electromechanical issues through root cause analysis and implement effective corrective actions

Contribute to configuration management and documentation control, maintaining clear versioning of CAD files, assemblies, and design revisions

Build and maintain engineering rigor by contributing to the development of company-wide best practices, including CAD standards, documentation protocols, and hardware management processes. Write detailed build documentation and collaborate hands-on with technicians during hardware integration and assembly

Qualification

Mechanical EngineeringStructural Analysis3D CAD (SolidWorks)Design for ManufacturabilityFEA AnalysisGD&T PrinciplesAircraft Design ExperiencePrototypingRoot Cause AnalysisCross-functional Collaboration

Required

Bachelor's degree in Mechanical Engineering, Aerospace Engineering, or a related discipline

8+ years of mechanical design experience, working directly with aircraft design

Minimum 3 year of hands-on experience in structural analysis

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

Experience analyzing primary and secondary aircraft structures using industry-standard tools and methods

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

Must be a U.S. Person (citizen or permanent resident) and able to work on-site in San Diego

Preferred

10+ years' of professional mechanical design experience, working directly with aircraft structural design, and analysis

5+ of hands-on experience in structural analysis & in the design of primary and secondary aircraft structures

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

Benefits

Comprehensive medical, dental, and visions plans

401(k) Retirement Savings Plan to invest in your long-term retirement goals

Equity grants for new hires

Unlimited PTO

Extremely generous company holiday calendar, including a holiday hiatus in November, & December.

Generous Parental Leave

Lifestyle Spending Account

FSA

DCFSA

HSA

Hospital Indemnity insurance

Critical Illness insurance

Accident insurance

Basic Life/AD&D, short-term and long-term disability insurance, 100% covered by Firestorm. Plus, the option to purchase additional life insurance for you and your family.

Mental Health Resources: We provide free mental health resources 24/7 including therapy and more. Additional work-life services, such as free legal and financial support, are available to you as well.