Mechanical Engineer

Harmattan AI; Austin (TX); On-site; USD 110,000 - 180,000; Full time

Job summary

Harmattan AI is seeking a Mechanical Engineer for its Airframe team to design UAV platforms and subsystems from concept through production. You will own system-level constraints, work with R&D colleagues to integrate sensors and electronics, and drive testing and validation in demanding environments.

The role requires a Master’s in mechanical/aerospace engineering and hands-on experience in UAVs or defence settings, with SolidWorks and FEA proficiency, and a strong grasp of manufacturing

Qualifications

• Master’s degree in Mechanical Engineering, Aerospace Engineering, or related field.
• Proven experience designing and prototyping mechanical systems, ideally within UAVs, robotics, or defence applications.
• Proficiency in CAD software (SolidWorks); experience with structural and thermal analysis tools (FEA) is a strong advantage.
• Strong understanding of manufacturing processes, including high-precision machining and plastic injection moulding.
• Excellent written and verbal communication skills, with the ability to clearly document complex technical concepts and lead cross-functional discussions.
• Full commitment to Harmattan AI’s mission, vision, and growth plans, with a willingness to go the extra mile in pursuit of operational excellence.

Responsibilities

• Design and prototype UAV platforms and complex subsystems from scratch, ensuring durability, efficiency, and performance.
• Take full ownership of system-level constraints, including thermal management, mass budget, COGS, and environmental sealing.
• Work closely with R&D teams (Electrical, Software, and Industrialisation) to ensure mechanical integration of sensors, payloads, and electronics.
• Conduct rigorous testing, including stress and failure analysis, and develop tools to validate designs for extreme environments.
• Manage delivery packages and technical specifications with precision to meet deadlines.
• Oversee manufacturing with suppliers and external manufacturers, focusing on plastic injection moulding and precision machining.
• Maintain source of truth through Confluence and 2D/3D documentation for knowledge sharing and continuous improvement.

Skills

Mechanical design

Prototype development

CAD (SolidWorks)

Thermal analysis

Manufacturing knowledge

Documentation

Cross-functional collaboration

Education

Master’s degree in Mechanical/Aerospace Engineering

Tools

SolidWorks

FEA tools

Job description

About Us

Harmattan AI is a next-generation defense prime building autonomous and scalable defense systems. Following the close of a $200M Series B, valuing the company at $1.4 billion, we are expanding our teams and capabilities to deliver mission-critical systems to allied forces.

Our work is guided by clear values: building technologies with real-world impact, pursuing excellence in everything we do, setting ambitious goals, and taking on the hardest technical challenges. We operate in a demanding environment where rigor, ownership, and execution are expected.

About the Role

As a Mechanical Engineer on Harmattan AI’s Airframe team, you will design UAV platforms and subsystems in an autonomous, fast-paced environment. You will take ownership of projects from concept through to production, ensuring optimal performance, reliability, and manufacturability.

Responsibilities

• Design and prototype UAV platforms and complex subsystems from scratch, ensuring the right balance between durability, efficiency, and performance.

• Take full ownership of system-level constraints, including thermal management, mass budget (weight), COGS (cost), and environmental sealing (IP ratings).

• Work closely with R&D teams (Electrical, Software, and Industrialisation) to ensure seamless mechanical integration of sensors, payloads, and electronics.

• Conduct rigorous testing, including stress and failure analysis. Identify risks proactively and develop the necessary tools (test benches, calculation sheets, or scripts) to validate designs for operation in extreme environments.

• Manage your own delivery packages and technical specifications with precision, consistently meeting or exceeding requirements under tight deadlines.

• Oversee the manufacturing process by collaborating directly with suppliers and external manufacturers, with a focus on plastic injection moulding and precision machining, to ensure quality and schedule targets are achieved.

• Maintain the “source of truth” through Confluence and professional 2D/3D documentation. Document all designs, test results, and production workflows to support knowledge sharing and continuous improvement.

Candidate Requirements

• Master’s degree in Mechanical Engineering, Aerospace Engineering, or a related field.

• Proven experience designing and prototyping mechanical systems, ideally within UAVs, robotics, or defence applications.

• Proficiency in CAD software (e.g., SolidWorks); experience with structural and thermal analysis tools (FEA) is a strong advantage.

• Strong understanding of manufacturing processes, including high-precision machining and plastic injection moulding.

• Excellent written and verbal communication skills, with the ability to clearly document complex technical concepts and lead cross‑functional discussions.

• Full commitment to Harmattan AI’s mission, vision, and growth plans, with a willingness to go the extra mile in pursuit of operational excellence.

We look forward to hearing how you can help shape the future of autonomous defense systems at Harmattan AI.