Lead UAV Airframe Architect

Firestorm; San Diego (CA); On-site; USD 153,000 - 206,000; Full time

Benefits offered by this job

Medical, dental, vision plans

401(k) retirement plan

Equity grants for new hires

Unlimited PTO

Holiday calendar including November/De

Job summary

Firestorm, based in San Diego, is hiring a Principal Airframe Design Engineer to own the hardware lifecycle of airframe structures for UAV systems. The role requires a strong background in mechanical/aerospace design, with 10+ years experience, SolidWorks, DFM, and cross‑functional collaboration.

On-site work in San Diego is required; U.S. citizenship and ability to obtain a security clearance are prerequisites.

Qualifications

• Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, or a related discipline.
• 10+ years of mechanical design experience, working directly withaircraftdesign.
• Proven track record of taking complex mechanical assemblies from concept to production.
• Strong foundationin mechanical engineering fundamentals; structures, fluid systems, thermal management, and mechanisms.
• Hands-on design engineering experience, with proven application of design-for-manufacturability (DFM) principles.
• Demonstrated ability to perform structural modeling and analysis of mechanical components and assemblies.
• Proficiencyin 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.
• Demonstrated technical leadership, with a proventrack recordof mentoring junior and mid‑level engineers, conducting rigorous design reviews, and elevating the technical standards of a growing engineering organization.
• U.S. Citizenship and ability to obtain and maintain a U.S. Government security clearance.

Responsibilities

• Lead mechanical design efforts for UAV subsystems across the entire product lifecycle: concept, prototyping, testing, production, and field support.
• Develop innovative, manufacturable airframe designsoptimizedfor UAV flight performance under varying operational conditions, ensuring structural, dynamic,thermaland functional requirements are met through rigorous analysis and validation.
• Analyze initial aerostructure designs against preliminary mass properties targets and strength and stiffness requirements.
• Create andmaintainhigh-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 ofaircraftprimary and secondary structures in the airframe, frominitialconcept through production.
• Develop and champion innovative structural solutions tooptimize weight, cost, and performance.
• Develop structural requirements, specifications, and test plans (DVP&R).
• Review of static & dynamic load inputs, materialpropertiesand test results.
• 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 andprovidingrobust design solutions.
• 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.
• Owntechnical 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,maintainingclear versioning of CAD files, assemblies, and design revisions.
• Build andmaintainengineering rigor by contributing to the development of company‑wide bestpractices, including CAD standards, documentation protocols, and hardware management processes. Write detailed build documentation and collaborate hands‑on with technicians during hardware integration and assembly.
• Cultivate a high‑performing design culture by mentoring junior and mid‑level engineers, leading technical design reviews, and formalizing company‑wide standards for airframe architecture.

Skills

Mechanical design

Aerospace integration

DFM

SolidWorks

GD&T

PCBAs integration

Wiring harnesses

Team mentoring

Engineering leadership

Structural analysis

First-order analysis

Education

Bachelors in Mechanical or Aerospace Engineering

Tools

SolidWorks

Job description

Firestorm, based in San Diego, is hiring a Principal Airframe Design Engineer to own the hardware lifecycle of airframe structures for UAV systems. The role requires a strong background in mechanical/aerospace design, with 10+ years experience, SolidWorks, DFM, and cross‑functional collaboration.

On-site work in San Diego is required; U.S. citizenship and ability to obtain a security clearance are prerequisites.