Senior UAV Systems Designer

Senior Mechanical Design Engineer

We are seeking a seasoned mechanical design engineer to spearhead the development of cutting-edge Hybrid UAV systems and subsystems. The ideal candidate will possess exceptional skills in CAD-based mechanical design, with a strong emphasis on manufacturability, integration readiness, and cross-functional collaboration.

Key Responsibilities:

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• CAD-Based Mechanical Design & Ownership">

The successful candidate will lead the mechanical design of Hybrid UAV subsystems and payload interfaces using advanced parametric CAD tools, such as PTC Creo. This will involve developing and maintaining complex CAD trees, system layouts, and 3D model integrity across revisions.

The chosen individual will drive modular and scalable design practices that align with product architecture, ensuring seamless integration and efficient production processes.

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• TAD (Tooling & Assembly Definition)">

Experience with TAD principles and hands-on experience in tooling and assembly strategies is essential for this role. The candidate will be responsible for preparing assembly BOMs, jigs, and fixture interfaces, as well as supporting design-to-assembly planning.

This involves contributing to design improvements based on ease of assembly, maintainability, and ergonomics, ensuring that our products meet the highest standards of quality and performance.

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• PLM Integration">

A deep understanding of Product Lifecycle Management (PLM) systems for version control, workflows, and digital thread management is crucial for this position. The successful candidate will be experienced in PLM/PDM platforms, ideally Windchill, and able to manage part structures, release cycles, and change management efficiently.

This includes collaborating with analysis teams to interpret FEA results and optimize design based on structural feedback, ensuring that our products meet stringent safety and performance requirements.

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• Structural Design & Collaboration">

The ideal candidate will possess a sound understanding of structural analysis fundamentals, including loads, boundary conditions, safety factors, fastener design, and more. They will be able to collaborate effectively with analysis teams to interpret FEA results and optimize design based on structural feedback.

This involves working closely with colleagues to identify areas for improvement and implementing design changes that enhance performance, reduce weight, and increase efficiency.

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• Material Engineering & Manufacturability">

Strong knowledge of materials, including metals, polymers, and composites, is essential for this role. The successful candidate will be able to evaluate designs for manufacturability, cost efficiency, and reliability using DFM, DFX, and material selection tools.

This includes prior experience working with high-performance materials, injection molding, and machining processes, as well as evaluating designs for additive manufacturing and 3D printing.

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• Additive Manufacturing & 3D Printing">

The ideal candidate will be well-versed in 3D printing techniques, including FDM, SLA, SLS, MJF, and DMLS. They will be able to select suitable printer types, grain structures, material properties, and post-processing requirements based on the use-case.

This involves collaborating with colleagues to develop optimized 3D printing solutions that meet specific performance, weight, and cost requirements.

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• Cross-Functional Collaboration">

The successful candidate will work closely with systems engineering, integration, sourcing, testing, and manufacturing teams to ensure seamless integration and efficient production processes.

This involves taking ownership of design deliverables, resolving cross-domain design issues, and ensuring on-time maturity of the mechanical stack.

The ideal candidate will also support Validation & Verification activities and ensure that mechanical designs are compliant with technical specs and regulatory needs.

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• Root Cause Analysis">

The successful candidate will be capable of understanding physical behavior, correlating with design definition, and deriving root causes in collaboration with CFT.

This involves analyzing design data, identifying areas for improvement, and implementing design changes that enhance performance, reduce weight, and increase efficiency.

Requirements:

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• Bachelor's or master's degree in mechanical engineering, Aerospace Engineering, or a related discipline.">

The ideal candidate will have at least 8 years of experience in mechanical product design, preferably in aerospace, UAVs, or robotics. Proficiency in 3D CAD modeling, TAD, and GD&T is essential for this role.

This includes experience in PLM/PDM platforms, ideally Windchill, as well as exposure to FEA results interpretation and collaborative optimization with analysts.

The successful candidate will also have knowledge of DFX, DFM, and high-performance material-process pairing, as well as hands-on experience with 3D printing tools and decision-making for rapid prototyping vs. end-use applications.

Benefits:

The successful candidate will enjoy a competitive salary and benefits package, as well as opportunities for career growth and professional development.

This includes access to state-of-the-art facilities and equipment, as well as a dynamic and supportive team environment that encourages innovation and creativity.

About Us:

We are a leading company in the UAV industry, dedicated to delivering innovative and reliable solutions to our customers. We value our employees and offer a range of benefits and perks to support their well-being and success.

Contact Us:

If you are a motivated and experienced mechanical design engineer looking for a new challenge, please submit your application today. We look forward to hearing from you

Skill Keywords:

senior mechanical design engineer uav hybrid systems subsystems cad-based mechanical design tadd tooling assembly definition plm integration windchill fea results structural analysis materials manufacturability cost efficiency reliability dff dfx high-performance material-process pairing 3d printing additive manufacturing rapid prototyping end-use applications