Senior Mech Design Engineer, Battery & Electronics

Zipline; South San Francisco (CA); On-site; USD 160,000 - 240,000; Full time

Job summary

Zipline is seeking an experienced Senior/Staff Mechanical Engineer to own the mechanical hardware for autonomous delivery aircraft. You will lead design of battery enclosures, power electronics housings, and related busbars, working with cross‑functional teams to meet performance, reliability, manufacturability, and cost targets.

You will mentor engineering teams, drive design reviews, and develop verification plans covering environmental, vibration, fatigue, thermal, and EMI/EMC testing.

Qualifications

• Experience delivering electro‑mechanical hardware from concept to production.
• Expert CAD and documentation for 20–100+ part assemblies.
• Strong skills in GD&T, tolerance stackups, FEA, and test planning.

Responsibilities

• Own end‑to‑end mechanical hardware delivery from requirements to production sustainment.
• Design enclosures, housings, busbars and power distribution hardware.
• Develop architectures for vibration, thermal, EMI, and safety in flight‑critical systems.
• Create analyses (trade studies, hand calcs, FEA) to support design decisions.
• Produce CAD assemblies, drawings, GD&T, and manufacturing docs; lead reviews.
• Plan and execute verification tests; design fixtures and drive corrective actions.

Skills

Electro‑mechanical design

CAD mastery (NX/SolidWorks)

GD&T & tolerance analysis

Thermal, vibration, EMI analysis

Supplier development

Strong written and verbal comms

System-level integration

Tools

NX

SolidWorks

FEA tools

Production drawings & GD&T

Job description

Zipline is seeking an experienced Senior/Staff Mechanical Engineer to own the mechanical hardware for autonomous delivery aircraft. You will lead design of battery enclosures, power electronics housings, and related busbars, working with cross‑functional teams to meet performance, reliability, manufacturability, and cost targets.

You will mentor engineering teams, drive design reviews, and develop verification plans covering environmental, vibration, fatigue, thermal, and EMI/EMC testing.