Mechanical Engineer - UAS

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 systemsDesign and fabricate multi-component assemblies for high-performance drone platformsPerform structural and FEA analysis to validate designs under flight, loads, and crashSelect and specify materials including CFRP composites, aluminum alloys, and engineering plastics for weight-critical applicationsIntegrate propulsion system components including motor mounts, ESC thermal management, and propeller clearance envelopesConduct mass properties analysis (CG, MOI) and coordinate with flight systems team to maintain acceptable flight dynamicsDesign vibration isolation solutions to protect sensitive electronics (IMU, cameras, RF systems) on propeller-driven airframesDevelop and maintain technical drawings with GD&T callouts per ASME Y14.5 standardsBuild, test, and iterate hardware rapidly using real-world feedback from flight operationsSupport MIL-STD-810 environmental testing (shock, vibration, temperature, humidity) and implement design improvementsCoordinate mechanical/electrical interface design including wiring harness routing, connector placement, and PCB mounting provisionsDrive designs from prototype through production (DFM/DFA, BOM, & build documentation)Minimum Qualifications:3 years of hands-on mechanical engineering experienceProven experience designing and fabricating real hardware systemsStrong 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 Y14.5Experience with lightweight structural materials including CFRP composites or aluminum alloysFamiliarity with DFM/DFA and hands-on prototype fabrication (CNC machining, FDM, SLA)Understanding of rotating propulsion system mechanics, vibration, and dynamic loadingAbility to work independently and take ownership of ambiguous design problemsPreferred Qualifications:Hands-on experience building, repairing, or flying FPV or tactical UAS platformsFamiliarity with MIL-STD-810 test methods and environmental qualification requirementsExperience with mass properties management and CG/MOI analysis for UAS platformsKnowledge of battery mechanical integration and thermal management in UAS airframesExperience coordinating with external machine shops or composite fabricatorsSolidWorks CSWA or CSWP certificationFamiliarity with payload integration for ISR or EW systems on tactical UxSExperience working in fast-paced R&D or defense environmentsClearance Requirements: None required (must be a U.S. Person eligible to work on ITAR-controlled programs)Required Background Check: HireRight background check & drug screeningType of Employment: Part-Time (with potential to transition to full time)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.