Mechanical Engineer - UAS

T3i, Inc.; San Antonio (TX); On-site; USD 80,000 - 150,000; Part time

Job summary

T3i, Inc. is seeking a Mechanical Engineer to own the mechanical architecture of our Blackfoot drone platform, from concept through production. You will design, fabricate, test, and iterate airframes, propulsion integration, payload bays, and structural hardware.

Work hands-on in the shop and in flight testing, applying GD&T and fast iteration in a defense-focused, fast-moving environment. A strong background in lightweight materials and MIL-STD-810 testing is preferred.

Qualifications

• 3 years of hands-on mechanical engineering experience.
• Experience designing and fabricating real hardware systems.
• Strong CAD proficiency (SolidWorks preferred; CATIA, Fusion 360, or NX accepted).
• Demonstrated FEA experience (SolidWorks Simulation, ANSYS, or Abaqus).
• Working knowledge of GD&T per ASME Y14.5.
• Lightweight materials such as CFRP or aluminum alloys.

Responsibilities

• Support mechanical design across airframe, motor mounts, payload bays, & landing systems.
• Design and fabricate multi-component assemblies for high-performance drone platforms.
• Perform structural and FEA analysis to validate designs under flight loads and crash.
• Select materials including CFRP, aluminum, and engineering plastics for weight-critical applications.
• Integrate propulsion system components and manage thermal/envelope considerations.
• Develop and maintain technical drawings with GD&T callouts per ASME Y14.5.
• Build, test, and iterate hardware rapidly from prototype to production.
• Coordinate mechanical/electrical interface design and PCB mounting provisions.
• Drive DFMA, BOM, and build documentation for production readiness.

Skills

Mechanical design

SolidWorks

FEA analysis

GD&T (ASME Y14.5)

Prototyping / fabrication

Lightweight materials

Tools

SolidWorks

ANSYS

CATIA / Fusion 360 / NX

Job description

Job Summary:
T3i builds mission-critical unmanned systems designed to improve US forces operational and lethal capabilities on the battlefield. Our Blackfoot platform is a tactical FPV drone system engineered for reliability, adaptability, and rapid deployment. We operate in tight feedback loops between design, build, and field use, where hardware decisions directly impact mission outcomes.

Job Summary:
T3i builds mission-critical unmanned systems designed to improve US forces operational and lethal capabilities on the battlefield. Our Blackfoot platform is a tactical FPV drone system engineered for reliability, adaptability, and rapid deployment. We operate in tight feedback loops between design, build, and field use, where hardware decisions directly impact mission outcomes.
We are a small, fast-moving team that values ownership, technical depth, and execution. We're looking for a Mechanical Engineer (ME) to support the mechanical architecture of our drone systems, from concept through production.
The ME will design, fabricate, test, and iterate on complete mechanical systems including airframes, propulsion integration, payload bays, and structural hardware. The ME will work hands-on in the shop, in integration, and during flight testing, closing the loop between design intent and real-world performance.
Position Summary:
The ME will be responsible for the design, integration, testing, and continuous improvement of the mechanical systems supporting the Blackfoot platform. This role emphasizes hands-on development, rapid iteration, and system-level ownership across the full hardware lifecycle. The ideal candidate thrives in fast-paced environments, is comfortable working across mechanical and electrical boundaries, and contributes to building reliable, field-ready systems.
Primary Responsibilities:

• Support mechanical design across airframe, motor mounts, payload bays, & landing systems
• Design and fabricate multi-component assemblies for high-performance drone platforms
• Perform structural and FEA analysis to validate designs under flight, loads, and crash
• Select and specify materials including CFRP composites, aluminum alloys, and engineering plastics for weight-critical applications
• Integrate propulsion system components including motor mounts, ESC thermal management, and propeller clearance envelopes
• Conduct mass properties analysis (CG, MOI) and coordinate with flight systems team to maintain acceptable flight dynamics
• Design vibration isolation solutions to protect sensitive electronics (IMU, cameras, RF systems) on propeller-driven airframes
• Develop and maintain technical drawings with GD&T callouts per ASME Y14.5 standards
• Build, test, and iterate hardware rapidly using real-world feedback from flight operations
• Support MIL-STD-810 environmental testing (shock, vibration, temperature, humidity) and implement design improvements
• Coordinate mechanical/electrical interface design including wiring harness routing, connector placement, and PCB mounting provisions
• Drive designs from prototype through production (DFM/DFA, BOM, & build documentation)

Minimum Qualifications:

• 3 years of hands-on mechanical engineering experience
• Proven experience designing and fabricating real hardware systems
• Strong CAD proficiency (SolidWorks preferred; CATIA, Fusion 360, or NX accepted)
• Demonstrated FEA experience (SolidWorks Simulation, ANSYS, or Abaqus)
• Working knowledge of GD&T per ASME Y14.5
• Experience with lightweight structural materials including CFRP composites or aluminum alloys
• Familiarity with DFM/DFA and hands-on prototype fabrication (CNC machining, FDM, SLA)
• Understanding of rotating propulsion system mechanics, vibration, and dynamic loading
• Ability to work independently and take ownership of ambiguous design problems

Preferred Qualifications:

• Hands-on experience building, repairing, or flying FPV or tactical UAS platforms
• Familiarity with MIL-STD-810 test methods and environmental qualification requirements
• Experience with mass properties management and CG/MOI analysis for UAS platforms
• Knowledge of battery mechanical integration and thermal management in UAS airframes
• Experience coordinating with external machine shops or composite fabricators
• SolidWorks CSWA or CSWP certification
• Familiarity with payload integration for ISR or EW systems on tactical UxS
• Experience working in fast-paced R&D or defense environments

Clearance Requirements: Secret security clearance or be able to obtain one within 90 days of hire
Required Background Check: HireRight background check & drug screening
Type of Employment: Part-Time (with potential to transition to full time)
Compensation: Part-time $38-$72 per hour (Full-time equivalent $80,000 - $150,000) based on experience and qualifications
T3i Drug Free Workplace Statement:
As a Federal Government Contractor, T3i is required to strictly adhere to federally mandated drug-free workplace standards. To ensure compliance with this requirement, T3i conducts pre-employment drug screening for all new hire personnel (full time, part time, and independent contractor) and annual random drug screening for all current T3i personnel. Personnel who cannot pass drug screening are not eligible for employment with T3i.