Senior Mechanical Design EngineerFirestorm • San Diego, California, United States

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Senior Mechanical Design Engineer

Firestorm

San Diego, California, United States

San Diego, California, United States

Jetzt Bewerben

Über

Who We Are
At Firestorm, we're on a mission to revolutionize how defense solutions are designed and delivered. Our goal is to empower U.S. ally nations to effectively deter aggressors—regardless of their defense budget—through innovative, cost-efficient technologies. We call this vision "democratized deterrence." As a VC-backed company at the intersection of defense and Silicon Valley, we're pioneering the development of mission-adaptable aerial vehicles that put power back into the hands of operators. By prioritizing operator effectiveness, we're pioneering a new era of aerial vehicle design. We aim to upend the traditional defense procurement model by delivering world-class capabilities at a fraction of the usual cost. Join us at Firestorm as we redefine defense procurement, making cutting-edge technology accessible to all at a fraction of the cost.
About the Role
Firestorm is seeking a highly skilled Senior Mechanical Design Engineer to join our innovative engineering team in developing next-generation UAV systems. As a Mechanical Design Engineer at Firestorm, you will be responsible for the design, structural analysis, and build efforts of critical flight structures and mechanisms within our product line. You will be given ownership for the hardware product lifecycle of the airframe. You will be responsible for the design, analysis, and oversight of manufacturing and validation of primary structure.
In this role, you will play a pivotal role in developing mechanical components and subsystems that satisfy demanding criteria for performance, manufacturability, and cost. Your expertise will bridge advanced aerospace technology and practical engineering as you collaborate cross-functionally with electrical, manufacturing, and flight-test teams to ensure seamless integration of mechanical and electromechanical systems. In order to be successful in this role, you must be someone who is self-motivated, adaptable and is able to lead your own projects to completion in a fast-paced environment. Ideally, you have significant mechanical or structural design experience and a proven track record completing collaborative projects effectively.
A successful candidate will have proven experience delivering high-performance, mass-optimized hardware in rapid development environments, with a strong foundation in both mechanical design and structural analysis. Proficiency in 3D CAD, first-order hand calculations, and higher order analysis methods will be key to driving innovative solutions that enhance our UAV platform capabilities. As an individual contributor, you will directly influence the technical direction of your designs and help shape engineering best practices across projects. You will be engaged in all phases of the development lifecycle, from early concepts and prototyping through rigorous testing and production, in a fast-moving, high-impact setting.
What You'll Do

Support 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 mechanical designs optimized for UAV flight performance under varying operational conditions, ensuring structural, thermal, and functional requirements are met through rigorous analysis and validation.

Analyze initial aerostructures 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 structures and 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.

Required Qualifications

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 Qualifications

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

5+ of hands-on experience in structural analysis & in the design of primary structure for vehicles.

Hands-on experience with UAV or aerospace flight structures, including knowledge of rotary and fixed-wing platforms.

Proven ability to develop and execute mission-level simulations or analysis tools using MATLAB, Simulink, or similar environments

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.

Work Environment

Based at our Headquarters in San Diego, CA

This role requires an on-site presence

Must be able to lift up to 30 lbs. and wear appropriate PPE (as required)

Willingness to travel up to 10% domestically for testing and demonstrations

Ability to work flexible hours and travel to various testing locations as needed

Compensation US Salary Range: $136,000 - $178,000 USD
The posted salary range reflects an estimate based on a variety of compensation factors, including but not limited to relevant experience, education, certifications, specialized skills, geographic location, and business needs. Actual compensation may vary, and this range is subject to change as our compensation structure or market conditions evolve. Benefits & Perks Our culture fosters collaboration, respect, and trust, empowering passionate people to do their best work. We offer a competitive salary, comprehensive benefits, and opportunities for career growth. In addition to an opportunity to take part in an innovative, collaborative and fast-growing business with a highly motivated and skilled team, we also take pride in taking care of our employees. Here are just a few ways that we show our appreciation:

We offer 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

San Diego, California, United States

Sprachkenntnisse

English

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