Mechanical Engineer V/VI

Zone 5 Technologies; Fort Worth (TX); On-site; USD 165,000 - 207,000; Full time

Benefits offered by this job

Comprehensive benefits package

401(k) with company match

4 weeks of paid time off

12 annual holidays

Job summary

Zone 5 Technologies in Fort Worth, TX is seeking a senior Mechanical Engineer V/VI to lead the design and integration of advanced UAV mechanical systems, including airframes, propulsion, and payloads.

You will oversee prototyping, testing, and structural analysis, mentor junior engineers, ensure regulatory compliance, and drive cross‑functional collaboration with avionics, sensors, and software teams.

Qualifications

• Bachelor’s degree in Mechanical or Aerospace Engineering or equivalent.

Responsibilities

• Lead design of complex mechanical systems for UAVs, including airframes, propulsion, and payload integration.

Skills

CAD expertise

GD&T knowledge

DFMA experience

FEA expertise

Aerodynamics knowledge

Analytical skills

Mentoring

Project leadership

Education

Bachelor's degree in Mechanical or Aerospace Engineering

Tools

SolidWorks

DFMA tooling design

FEA software

CFD experience

Job description

At Zone 5 Technologies, we’re redefining what’s possible in unmanned aircraft systems. Our team of engineers and innovators is developing cutting‑edge autonomous solutions that push the boundaries of UAS technology, solving complex challenges that matter.

We’re building the future of UAS capabilities, and we’re looking for exceptional talent to join us. If you’re driven by hard problems, energized by rapid innovation, and ready to make an impact on next‑generation flight systems, you belong here.

We’re looking for a Mechanical Engineer V/VI for Unmanned Aircraft Systems (UAS), a senior‑level role responsible for leading the design, development, and implementation of advanced mechanical systems for UAVs. This position involves strategic oversight, innovative problem‑solving, and mentorship of junior engineers.

Key Responsibilities

• Strategic Design Leadership: Lead the design of complex mechanical systems for UAVs, including advanced airframes, propulsion systems, and payload integration.
• Advanced Prototyping and Testing: Oversee the development and testing of UAV prototypes, ensuring compliance with performance and reliability goals.
• Comprehensive Structural Analysis: Conduct and review in‑depth stress, strain, and fatigue analysis for UAV mechanical systems operating under extreme conditions.
• Thermal Management Expertise: Develop and implement innovative thermal systems for high‑performance UAVs.
• Cross‑Functional Integration: Lead collaboration with multidisciplinary teams to integrate mechanical systems with avionics, sensors, and software controls.
• Material Innovation: Drive research and development of advanced materials for UAV applications, focusing on composites and lightweight alloys.
• Failure Analysis and Solutions: Lead root cause analysis of mechanical failures and propose long‑term, impactful solutions.
• Regulatory Compliance Leadership: Ensure all designs meet and exceed UAS regulations and industry certifications.
• Research and Development: Spearhead R&D initiatives to advance UAS technologies, including autonomous navigation and advanced manufacturing techniques.
• Mentorship and Leadership: Provide technical guidance and mentorship to junior and mid‑level engineers.
• Documentation and Reporting: Author comprehensive technical documentation, including design reviews, test reports, and compliance certificates.

Qualifications

• Education: Bachelor’s degree in Mechanical or Aerospace Engineering, or equivalent experience.
• Experience: 10+ years in engineering roles.

Skills

• Advanced proficiency in CAD and mechanical design software (e.g., SolidWorks).
• Knowledge of geometric dimensioning and tolerancing (GD&T) and drafting.
• Experience with design for manufacturability (DFMA) and tooling design.
• Experience with finite element analysis (FEA) and other advanced simulation tools.
• Experience in fluid dynamics, thermodynamics, structural mechanics, and aerodynamics.
• Strong analytical and problem‑solving skills, and ability to mentor.
• Proven ability to drive innovation and manage complex engineering projects.

Preferred Qualifications

• Additional 5 years dedicated to UAV development.
• Advanced proficiency in CAD primarily for aerospace and UAS applications.
• Experience with advanced simulation tools (e.g., FEA, CFD).
• Expertise in structural mechanics, aerodynamics, and thermodynamics.
• In‑depth knowledge of UAV manufacturing processes, including 3D printing and advanced composite materials.
• Familiarity with advanced UAV‑specific regulations and broader aerospace certification processes (e.g., DO‑160, AS9100).

Pay and Benefits

Pay Range by Level for Fort Worth, Texas: Level V – $165k – $189k; Level VI – $189k – $207k. Pay range for this role: $165,000 – $207,000 USD.

Benefits

• Comprehensive benefit package options include medical, dental, vision, life, and more.
• 401(k) with company match.
• 4 weeks of paid time off each year.
• 12 annual company holidays.

Why Join Zone 5 Technologies?

• Innovative Environment: Work on cutting‑edge technology that is shaping the future of defense and aerospace.
• Collaborative Culture: Join a team of passionate professionals dedicated to pushing the boundaries of what’s possible.
• Career Growth: Opportunities for professional development and career advancement.

Legal & Equal Opportunity Statement

In compliance with federal law, all persons hired will be required to verify identity and eligibility to work in the United States and to complete the required employment eligibility verification form upon hire.

Zone 5 Technologies is a federal contractor and participates in E‑Verify to confirm employment eligibility. As required by law, we will verify the identity and employment authorization of all new employees using the E‑Verify system.

As set forth in Zone 5 Technologies’ Equal Employment Opportunity policy, we do not discriminate on the basis of any protected group status under any applicable law.