Senior Staff Aerostructures Design Engineer
Lead structural design and analysis for next-gen autonomous UAVs. Own CAD modeling, FEA, testing, and cross-functional integration from concept through production.
Senior Staff Engineer, Mechanical Design (R4486)
Designs complex electro-mechanical mechanisms for autonomous UAVs, owning full process from concept to testing. Requires 8+ years experience, BS in Mechanical/Aerospace Engineering, strong CAD/FEA skills, and cross-team collaboration.
167k – 250kDallas, TXSan Diego, CAHardware EngineeringOnsite8+ YOE
About the role
Responsibilities
- Design complex electro-mechanical mechanisms for autonomous aircraft
- Own the full design process: concept, CAD, tolerance analysis, material selection, and drawing release
- Perform structural and kinematic calculations and preliminary FEA
- Prototype, test, and iterate mechanism designs for functionality and reliability
- Collaborate with electrical, avionics, flight controls, and propulsion teams
- Mentor junior engineers and promote engineering excellence
- Support pre-production builds, prototype integration, and ground/flight testing
Required Qualifications
- B.S. in Mechanical/Aerospace Engineering
- 8+ years in mechanical or mechanism design
- Strong CAD skills (NX preferred)
- Kinematic analysis and optimization
- Structural analysis utilizing hand calculations and finite element methods
- FEA analysis: Modal, non-linear and linear, buckling, fatigue
- GD&T and tolerance stack-ups for mechanical systems
- Materials selection inclusive of alloys, heat treatments, allowables, and finishes
- Ability to work independently and lead in fast-paced, cross-functional teams
Preferred Qualifications
- Experience with UAVs, aircraft, or robotic systems
- Familiarity with electro-mechanical actuators
- Proficiency in FMEA, DOE, and root cause analysis
- Hands-on machine shop or mechanic experience (professional or hobby)
- RTCA DO-160, structural, or actuated mechanism testing experience
- Ability to thrive in startup, R&D, or defense innovation environments
Skills
NxCADFEAGD&TKinematic AnalysisStructural AnalysisTolerance Stack-UpsFmeaDoeUav Design
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