UAS Mechanical Design Engineer

COLSA; Madison (AL); On-site; USD 90,000 - 130,000; Full time

Benefits offered by this job

Medical

Dental

Vision

Life Insurance

Short-Term Disability

Long-Term Disability

401(k) with company match

Education Reimbursement

Paid Time Off

Job summary

COLSA Corporation is hiring an experienced UAS Mechanical Design Engineer in Madison, AL, onsite. You will design mechanical systems for sUAS, perform analyses, and drive designs from concept to production, using SolidWorks, PDM, and GD&T. U.S. citizenship and ability to obtain security clearance may be required.

The role emphasizes cross-functional collaboration with engineering and manufacturing, prototype testing, and environmental qualification to meet flight-critical requirements.

Qualifications

• Bachelor of Science degree in Mechanical Engineering, Aerospace Engineering, or a related engineering discipline.
• Minimum of 5 years of hand-on mechanical design and product development experience in aerospace, robotics, defense, or unmanned aircraft systems (UAS).
• Hands-on experience administering SolidWorks PDM Professional, including configuration management, engineering change workflows, revision control, and document management.
• Strong working knowledge of ASME Y14 drafting standards and Geometric Dimensioning and Tolerancing (GD&T).
• Experience taking UAS or similar aerospace hardware components from initial concept through qualification testing and into manufacturing or production.
• U.S. citizenship required; ability to obtain/maintain security clearance if required.

Responsibilities

• Develops mechanical designs, assemblies, and system architectures for sUAS platforms and flight-critical hardware components.
• Performs structural analyses, engineering trade studies, and design evaluations to support performance and mission requirements.
• Designs and integrates mechanical structures, assemblies, and hardware components using SolidWorks.
• Supports prototype development, hardware integration, ground and flight testing, and environmental qualification activities.
• Collaborates with engineering and manufacturing teams to refine designs for manufacturability, assembly, and repeatable production.
• Administers SolidWorks PDM Professional workflows to support engineering configuration management, document control, and revision tracking.
• Develops, reviews, and manages engineering change documentation (ECR/ECN/ECO) and related assessments.
• Ensures drawings and documentation comply with ASME Y14 and customer requirements.

Tools

SolidWorks

SolidWorks PDM Professional

ASME Y14 drafting standards

GD&T

Job description

Tracking Code: 9843-987

Posted Date: 10/26/2026

Job Location: Madison, Alabama

Location of Position: Madison, Alabama

Work Arrangement: On Site: 100%

Position Type: Full-Time/Regular

Clearance Required?: No

Level of Clearance Required: None

COLSA Corporation is seeking an experienced UAS Mechanical Design Engineer to support the design, development, integration, and testing of small unmanned aircraft systems (sUAS), including Group 1 and Group 2 UAS platforms. This position supports the full product development lifecycle, from initial concept and mechanical design through prototype development, testing, qualification, and transition to production.

Principal Duties And Responsibilities (Essential Functions)

• Develops mechanical designs, assemblies, and system architectures for sUAS platforms and flight-critical hardware components.
• Performs structural analyses, engineering trade studies, and design evaluations to support system performance, reliability, and mission requirements.
• Designs and integrates mechanical structures, assemblies, and hardware components using SolidWorks.
• Supports prototype development, hardware integration, ground and flight testing, and environmental qualification activities.
• Collaborates with engineering and manufacturing teams to refine designs for manufacturability, assembly, and repeatable production.
• Administers SolidWorks PDM Professional workflows to support engineering configuration management, document control, and revision tracking.
• Develops, reviews, and manages engineering change documentation, including Engineering Change Requests (ECRs), Engineering Change Notices (ECNs), and Engineering Change Orders (ECOs).
• Ensures engineering drawings, technical documentation, and design changes comply with ASME Y14 drafting standards and applicable customer requirements.

At COLSA, people are our most valuable resource and centered at our core value. We invite you to unite your talents with opportunity and be a part of our "Family of Professionals!" Learn about our employee-centric culture and benefits here: https://www.colsa.com/culture_benefits

Required Experience

Required Qualifications:

• Bachelor of Science degree in Mechanical Engineering, Aerospace Engineering, or a related engineering discipline.
• Minimum of 5 years of hand-on mechanical design and product development experience in aerospace, robotics, defense, or unmanned aircraft systems (UAS).
• Advanced proficiency in SolidWorks, including complex surface and solid modeling, top-down assembly design, sheet metal, and weldments.
• Strong working knowledge of ASME Y14 drafting standards and Geometric Dimensioning and Tolerancing (GD&T).
• Hands-on experience administering SolidWorks PDM Professional, including configuration management, engineering change workflows, revision control, and document management.
• Demonstrated experience developing, reviewing, and managing engineering change packages (ECR/ECN/ECO), including technical evaluations and manufacturing impact assessments.
• Experience taking UAS or similar aerospace hardware components from initial concept through qualification testing and into manufacturing or production.
• U.S. citizenship required. Must be able to complete a criminal background check and/or obtain and maintain a U.S. Government security clearance, if required for the position.

Preferred Qualifications

• Experience designing with aerospace-grade aluminum (6061, 7075), titanium, carbon fiber-reinforced polymers (CFRP), high-temperature engineering plastics (PEEK, ULTEM), and elastomeric vibration isolators.
• Experience with mass properties management, generative design, topology optimization, and weight reduction initiatives for endurance-critical aircraft.
• Hands-on fabrication experience using machine shop equipment (CNC routers, mills, lathes), industrial 3D printing technologies (SLS nylon, metal powder bed fusion, FDM), and composite mold fabrication and curing.
• Experience designing passive and active vibration isolation mounts for sensitive optical sensors, inertial measurement units (IMUs), and LiDAR payloads exposed to motor-induced vibrations.
• Familiarity with military and civilian UAS design guidelines and environmental testing standards, including MIL-STD-810H, STANAG 4703, and applicable FAA Part 107/Part 21 requirements.

Applicant selected will be subject to a government security investigation and must meet eligibility requirements for access to classified information. COLSA Corporation is an Equal Opportunity Employer, Minorities/Females/Veterans/Disabled. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, or national origin.

Salary Type

Annually

The salary range, if referenced, represents a good faith estimate. COLSA considers various factors when determining base salary offers, but not limited to, location, the role, function and associated responsibilities, a candidate’s particular combination of education, knowledge, skills, competencies, and experience, as well as contract-specific affordability and organizational requirements.

COLSA offers a comprehensive and customizeable benefits program which includes Medical, Dental, Vision, Life Insurance, Short-Term Disability, Long-Term Disability, Accidental Death & Dismemberment, Supplemental Income Protection Programs, 401(k) with company match, Flexible Spending Accounts, Employee Assistance Program, Education & Certification Reimbursement, Employee Discount Program, Paid Time Off and Holidays.

• Medical
• Dental
• Vision
• Life Insurance
• Short-Term Disability
• Long-Term Disability
• Accidental Death & Dismemberment
• Supplemental Income Protection Programs
• 401(k) with company match
• Flexible Spending Accounts
• Employee Assistance Program
• Education & Certification Reimbursement
• Employee Discount Program
• Paid Time Off and Holidays

This position will be posted for a minimum of 3 business days. If a candidate has not been selected at that time, it will continue to be posted until a suitable candidate is selected or the position is closed.