Senior Applications Engineer

Who We Are
At Firestorm, we’re on a mission to revolutionize how defense solutions are designed and delivered. Our goal is to empower U.S. ally nations to effectively deter aggressors — regardless of their defense budget — through innovative, cost-efficient technologies. We call this vision “democratized deterrence.” As a VC-backed company at the intersection of defense and Silicon Valley, we’re pioneering the development of mission-adaptable aerial vehicles that put power back into the hands of operators. By prioritizing operator effectiveness, we’re pioneering a new era of aerial vehicle design. We aim to upend the traditional defense procurement model by delivering world-class capabilities at a fraction of the usual cost. Join us at Firestorm as we redefine defense procurement, making cutting-edge technology accessible to all at a fraction of the cost. About the Role Firestorm Labs is seeking a Senior Applications Engineer (AE) to design and deliver high-performance, mission-specific parts and assemblies using SolidWorks (CAD), working directly with Department of Defense (DoD) customers in a deployed environment This is a hands-on, dynamic engineering role focused on additive manufacturing, reverse engineering, and field-based support using Firestorm’s mobile expeditionary manufacturing capability (MECC). The candidate fulfilling this role will modify existing designs, create new ones from scratch, and reverse engineer physical components for rapid prototyping and production in forward-operating environments. The role combines design engineering, customer-facing applications work, and on-site leadership.  What You'll Do

• Design custom mechanisms, structural components, and assemblies for both UAS and non-UAS applications using SolidWorks.
• Modify, optimize, and reverse engineer physical parts for additive manufacturing, specifically HP Multi Jet Fusion (MJF) production.
• Operate 3D scanning equipment to capture complex part geometries, clean up point clouds and meshes, and convert into solid models.
• Perform DFAM (Design for Additive Manufacturing) reviews and workshops with DoD customers and internal Firestorm teams.
• Conduct metrology, quality control inspections and part evaluation, using precision tools and techniques.
• Maintain a database of customer-submitted part files, build histories, and scanned geometries for tracking and re-use.
• Create technical specifications and work instructions for internally produced and third-party assemblies.
• Operate and maintain additive manufacturing systems, including daily, weekly, and monthly service tasks.
• Manage CAD data and file release workflows using systems such as SolidWorks PDM, ARENA, or Teamcenter.
• Set up, configure, and commission Firestorm’s mobile manufacturing container in deployed environments.
• Assist in the manufacturing and assembly of UAS platforms and related hardware.
• Communicate effectively with HQ stakeholders, escalating issues, and collaborating on technical solutions.
• Serve as a technical resource for Firestorm’s Business Development team, providing engineering insight during customer engagements, and proposal development.
• Help create and maintain technical documentation, user manuals, and troubleshooting guides to support customer use and internal operations.
• Document and escalate technical insights and field observations to inform product improvements, working closely with Software and Platform engineering teams.
• Author and deliver status reports, as well as technical updates to both internal stakeholders, and external government customers.
• Support internal teams at customer-facing events and demonstrations, occasionally assisting in representing the product to external stakeholders.

 Minimum Qualifications 

• Bachelor’s degree in Mechanical Engineering or a related field.
• Minimum 5 years of experience as a design or applications engineer, with hands-on experience in additive manufacturing.
• 2+ years of experience using metrology and inspection tools, with professional-level quality control knowledge.
• U.S. Citizenship required due to ITAR regulations & the ability to obtain and maintain a Department of Defense (DoD) security clearance
• Expert-level proficiency in SolidWorks, including part modeling, assemblies and technical drawings.
• Strong technical writing skills for documenting systems, procedures, and troubleshooting steps.
• Effective collaborator with the ability to work across engineering disciplines and with field operations teams.

 Preferred Qualifications 

• 7+ years of experience as a Applications Engineer, prefer