Junior R&D Engineer

PDW; Huntsville (AL); On-site; USD 55,000 - 75,000; Full time

Benefits offered by this job

Medical coverage

On-site gym

401(k) plan

Paid time off

EAP

Job summary

Performance Drone Works (PDW) is seeking a Junior R&D Engineer in Huntsville, AL to help turn concepts into functional prototypes. You will design, prototype, test, and refine mechanical systems with guidance from senior engineers.

The role emphasizes hands-on fabrication, rapid iteration, and documentation of results. Work with 3D CAD, additive manufacturing, and test fixtures; collaborate on electronics integration and tool development.

Qualifications

• Bachelor's degree or equivalent in mechanical engineering or related field.
• Experience with mechanical fabrication, prototype development, assembly, or testing.
• Working knowledge of 3D CAD software such as SolidWorks or similar.
• Experience with additive manufacturing (FDM and/or SLS).
• Strong mechanical aptitude and hands-on problem-solving ability.
• Ability to use hand tools, measurement equipment, and fabrication equipment.
• Ability to follow engineering direction and procedures with increasing independence.
• Ability to document technical work, test configurations, and results.
• Willingness to learn new engineering tools, processes, and test methods.
• Must be able to obtain and maintain a U.S. Security Clearance.

Responsibilities

• Create and modify 3D CAD models for prototype components, assemblies and test fixtures.
• Modify existing designs based on prototype testing and feedback.
• Perform basic tolerance analysis and apply dimensions to prototypes.
• Communicate design options, advantages, risks, and trade-offs.
• Develop parts for additive manufacturing, machining and related processes.
• Translate CAD concepts into functional prototypes.
• Build, modify, assemble, and troubleshoot prototype systems.
• Utilize rapid prototyping methods to support development.
• Support electronics integration including mounting and cable routing.
• Record test configurations, procedures, and results clearly.
• Identify failure modes and assist root-cause investigations.
• Suggest design or process improvements based on test results.

Skills

3D CAD (SolidWorks)

Additive manufacturing

Hands-on hardware

Measurement tools

Documentation

Electromechanical understanding

Education

Bachelor's degree in Mechanical Engineering or related field

Tools

SolidWorks

SLS & FDM machines

Job description

Performance Drone Works (PDW) is building the next generation of tactical robotic systems used across defense, national security, and public safety missions. We are building a new center of engineering excellence to design our new category of tactical robotic systems and the industrial capacity to deliver them, bringing decisive airpower into the hands of every operator. We are not here to make promises; we are here to deliver real systems with real capabilities for real missions.

You will join a team of operators, engineers, and builders who solve hard problems with humility and focus. We design and produce multi-mission aerial systems that operators trust to perform in real-world conditions, reliably, repeatedly, and at scale. Our approach is grounded in operator-centered design, rapid iteration from field use, and U.S.-based manufacturing. Weoperateby a clear set of values: Mission First, Aim Farther, Own It, Win Together. This is how we build advantage and how we help protect our service members, our communities, and our country.

Now, we’re entering a new phase of growth and are looking for J unior R&D Engineer to support the rapid development, prototyping, integration, and testing of new technologies, subsystems, and product concepts. This is a highly hands-on engineering role intended for an individual who enjoys building and testing hardware while developing stronger mechanical design, CAD, prototyping, and engineering analysis skills. Working with guidance from senior engineers, the Junior R&D Engineer will help turn early concepts into functional prototypes, execute testing, document results, and iterate designs based on real-world performance.

What You'll Do

Mechanical Design & CAD

• Create and modify 3D CAD models for prototype components, assemblies, test fixtures, and lab hardware.
• Modify existing designs based on prototype fit checks, testing results, manufacturing feedback, and engineering direction.
• Perform basic tolerance analysis and apply appropriate dimensions and clearances to prototype components.
• Create and compare design concepts and communicate the advantages, disadvantages, and risks associated with each approach.
• Develop increasing proficiency in designing components for additive manufacturing, machining, and other applicable manufacturing processes.

Rapid Prototyping & Fabrication

• Translate engineering concepts and CAD designs into functional prototypes.
• Build, modify, assemble, and troubleshoot mechanical and electromechanical prototype systems.
• Use additive manufacturing, machining, hand fabrication, and other rapid-prototyping methods to support development activities.
• Design and fabricate test fixtures, assembly fixtures, jigs, adapters, and other development tools.
• Support electronics integration including component mounting, mechanical final assembly, cable routing, and basic wiring.
• Perform prototype fit checks and identify mechanical interference, assembly, tolerance, and serviceability issues.
• Work directly with engineers to rapidly iterate prototype designs based on build and test results.
• Execute mechanical, environmental, functional, and system-level testing as applicable.
• Accurately record test configurations, procedures, observations, measurements, failures, and results.
• Identify failure modes and assist with root-cause investigations.
• Recommend design or process improvements based on test results and observed performance.
• Generate concise engineering test reports documenting test objectives, configuration, methodology, results, conclusions, and recommended next steps.

Additive Manufacturing & R&D Lab Support

• Maintain technical ownership and proficiency with R&D additive-manufacturing equipment, including SLS and FDM systems.
• Prepare, operate, maintain, troubleshoot, and calibrate additive-manufacturing equipment.
• Develop and document repeatable printing, post-processing, maintenance, and calibration procedures.
• Evaluate new materials, print parameters, equipment, and processes that improve prototype quality.
• Maintain an organized and functional R&D prototyping environment.
• Assist with maintaining appropriate prototype materials, tools, equipment spare parts, and consumables.
• Help continuously improve R&D lab processes, equipment capabilities, and development workflows.

Requirements

• Bachelor's degree in Mechanical Engineering, Engineering Technology, or a technically related field; or equivalent combination of technical education and relevant hands-on engineering experience.
• Experience with mechanical fabrication, prototype development, assembly, or testing.
• Working knowledge of 3D CAD software such as SolidWorks or similar software.
• Experience with additive manufacturing, including FDM and/or SLS technologies.
• Strong mechanical aptitude and demonstrated hands-on problem-solving ability.
• Ability to use common hand tools, measurement equipment, and fabrication equipment.
• Ability to follow engineering direction, test procedures, and standard operating procedures while completing assigned tasks with increasing independence.
• Ability to clearly document technical work, test configurations, results, and conclusions.
• Ability and willingness to learn new engineering tools, manufacturing processes, and test methods.
• Must have the ability to obtain and maintain a U.S. Security Clearance.

Preferred

• Experience designing parts specifically for additive manufacturing.
• Experience with machining, sheet metal, composites, injection molding, or other manufacturing processes.
• Experience designing and building test fixtures and assembly tooling.
• Experience performing mechanical or electromechanical testing and documenting results.
• Experience with basic electronics integration, wiring, connectors, and mechanical packaging of electronics.
• Experience with UAV aircraft, FPV systems, robotics, or other electromechanical systems.

Physical Requirements

The physical demands described here are representative of those that must be met to successfully perform the essential functions of the job. Ability to sit, stand, bend, reach, climb, and move about regularly throughout the day and lift / carry up to 50 pounds. Must have manual dexterity to operate standard machine shop equipment . Must be physically capable of tolerating chemicals (with PPE).

This position typically operates in a standard office setting and manufacturing environment. This role requires use of standard office equipment and may involve exposure machining and prototyping equipment, tools, hazardous chemicals or materials. This position may have exposure to outdoor weather conditions, noise, and non-climate-controlled environments. May require the use of personal protective equipment (PPE) depending on the environment. This is a fast-paced work environment and requires cross departmental collaboration with independent and team-based responsibilities. Standard works hours for this position are 8:30am to 5:00pm with occasional overtime as operational needs demand.

PDW values our team, and we offer a compensation package reflective of your experience and capabilities. Benefits include:

• Comprehensive BCBS medical, dental, and vision coverage; 80% sponsored by the company.
• Safe Harbor 401(K) with company match.
• On-site gym at our Huntsville, AL and Denver, CO locations.
• Employerprovided life insurance.
• Robust Employee Assistance Program (EAP).
• A work environment that encourages teamwork and innovation.
• Competitive salary, generous paid time off (PTO), and flexible leave options.

EEO Statement

PDW is an equal opportunity employer that upholds all federal and state non-discrimination laws. We ensure a fair and unbiased evaluation for employment for all qualified candidates regardless of race, color, religion, age, sex, sexual orientation, gender identity, national origin, marital status, medical condition, disability, genetic information, veteran status, or any other characteristic protected by law.