Senior Mechanical Engineer

Position SummaryApium Swarm Robotics (ASR) is revolutionizing swarm autonomy software for air, surface, undersea, and ground vehicles operating across dual-use commercial and defense environments. Our systems are deployed on real platforms, tested in the field, and delivered to customers operating in complex, uncertain, and safety-critical conditions.We do not build research prototypes or slideware. Our software is integrated into real vehicles, tested in the field, and delivered to customers who depend on operational reliability, speed of execution, and mission relevance. We prioritize performance over hype.ASR systems represent the next phase in autonomy: collaborative swarming. These are not like pre-programmed drones for light shows. We are creating real-time cooperative management that lets one operator control dozens to hundreds of vehicles in real-time with the ease of controlling a single vehicle. As such, this role requires comfort with responsibility, ambiguity, and operational accountability.ASR seeks a mechanical engineer to join our hardware development team. This role targets a designer and builder capable of owning the full lifecycle of physical hardware — from concept through manufacture — across a range of enclosure, packaging, and drone integration products. Primary responsibilities include the design and manufacture of Dongle Cases and Bridge Boxes, the ruggedized electronic enclosures central to ASR’s ground station and communications infrastructure.Unlike many hardware roles, ASR’s compact swarm platform allows mechanical work to be prototyped and iterated quickly, with in-house 3D printing and a bias toward rapid, field-testable designs. Travel may be required for field testing and demonstrations which will allow you to witness firsthand how your hardware performs as dozens of drones take flight.Position will also encompass the design, testing, and manufacture of drone attachments and physical modifications — ranging from simple mounting brackets to complex multi-axis actuators — as well as the development of mechanisms supporting ASR’s “swarm in a box” concept: self-contained, rapidly deployable swarm systems with integrated logistics, charging, and launch capability.The role includes responsibility for ASR’s swarm packaging program: specifying, sourcing, and customizing Pelican case configurations and precision-cut foam inserts to ensure vehicles and ground equipment survive transport and deployment in demanding field environments.Essential Duties And ResponsibilitiesDesign and oversee manufacture of Dongle Cases, Bridge Boxes, and other ruggedized electronic enclosuresSpecify, source, and customize swarm packaging solutions including Pelican cases and precision foam insertsDesign, test, and manufacture drone attachments and physical modifications, from simple brackets to actuated mechanismsCollaborate with the engineering team on “swarm in a box” mechanism design, prototyping, and field validationRequired QualificationsProficiency in 3D CAD modeling software (SolidWorks, Fusion 360, or equivalent)Hands-on experience with FDM and/or resin 3D printing, including material selection and print optimizationPractical knowledge of 3D printing materials including PLA, PETG, ABS, TPU, Nylon, and composite variantsExperience building, flying, or modifying UAVs and familiarity with drone hardware ecosystemsUnderstanding of robotics mechanisms including servo and stepper motor integration, linkages, and motion systemsIndustrial design competency including IP/ingress protection ratings, vibration tolerance, thermal management, and impact resistanceBasic understanding of LiPo and lithium-ion battery systems, charging architectures, and associated safety considerationsExperience designing enclosures and hardware for field deployment, including considerations for sealing, ingress protection, and structural durabilityAbility to work effectively within a cross-functional team alongside software, electrical, and systems engineersComfort working independently with limited oversightAbility to remain calm and effective under operational pressureAdditional Desired QualificationsBS in Mechanical Engineering or related fieldExperience with injection molding, vacuum forming, or other production-scale manufacturing processesExperience with CNC machining, laser cutting, or other subtractive and precision fabrication methodsFamiliarity with MIL-SPEC, MIL-STD-810, or equivalent environmental qualification standardsExperience with EMI/RFI shielding considerations in enclosure designExperience specifying and working with custom foam fabrication, including CNC-cut foam inserts for equipment casesExperience with FPV racing, custom drone builds, or UAS competition platformsBasic electronics knowledge sufficient to collaborate on PCB mounting, connector selection, and wire routing within enclosuresExperience with GD&T (Geometric Dimensioning and Tolerancing) and tolerance stack-up analysisFamiliarity with pneumatic, hydraulic, or cable-driven actuation systemsExperience with finite element analysis (FEA) or computational fluid dynamics (CFD) toolsPrevious experience supporting hardware programs in defense, aerospace, or other safety-critical environmentsStrong mechanical, electrical, or systems troubleshooting skillsU.S. security clearance or ability to obtain onePhysical Requirements And Working ConditionsMust be able to walk, stand, and navigate large indoor and outdoor facilities for extended periods of time.Ability to lift, carry, and move materials and equipment weighing up to 25 lbs on a regular basis.Use of personal protective equipment (PPE) may be required in designated areas or when performing specific tasks, in accordance with safety protocols and company policy.May be required to climb ladders, stoop, kneel, or crouch during inspections, maintenance walk-throughs, or emergency response situations.Regular exposure to facility operations including noise, dust, temperature fluctuations, and industrial equipment.Occasional off-hours or weekend work required for emergency facility responses or projects as neededRequires frequent use of a computer and other standard office equipment for documentation, communication, and coordination tasks.Requirement to travel up to 25% of the time, based on customer integration needs and operational requirements.Background CheckThis position will require successfully completing a post-offer background check. Qualified candidates with a criminal history will be considered and are not automatically disqualified, consistent with federal and state law.EEO and ITAR/EAR Work Authorization DisclosureRed Cat Holdings provides equal employment opportunities (EEO) to all employees and applicants for employment and prohibits discrimination and harassment of any type without regard to race, color, religion, age, sex, national origin, disability status, genetics, protected veteran status, sexual orientation, gender identity or expression, or any other characteristic protected by federal, state or local laws. This position requires direct or indirect access to hardware, software, technology or technical data controlled under the International Traffic in Arms Regulations (ITAR) and the Export Administration Regulations (EAR). Successful candidates for positions subject to ITAR/EAR restrictions must provide proof of U.S. Citizenship or Permanent Residence and must not require sponsorship for export-restricted work authorization.E-VerifyThe company participates E-Verify ensure eligibility for employment and compliance with Right to Work rules.Compensation: Base pay, plus generous annual equity package and potential bonuses.