Senior Mechanical Design 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 is seeking a highly skilled Senior Mechanical Design Engineer to join our innovative engineering team in developing next-generation UAV systems. As a Mechanical Design Engineer at Firestorm, you will be responsible for the design, structural analysis, and build efforts of critical flight structures and mechanisms within our product line. You will be given ownership for the hardware product lifecycle of the airframe. You will be responsible for the design, analysis, and oversight of manufacturing and validation of primary structure.
A successful candidate will have proven experience delivering high-performance, mass-optimized hardware in rapid development environments, with a strong foundation in both mechanical design and structural analysis. Proficiency in 3D CAD, first-order hand calculations, and higher order analysis methods will be key to driving innovative solutions that enhance our UAV platform capabilities. As an individual contributor, you will directly influence the technical direction of your designs and help shape engineering best practices across projects. You will be engaged in all phases of the development lifecycle, from early concepts and prototyping through rigorous testing and production, in a fast-moving, high-impact setting.

What You’ll Do

• Lead mechanical design and structural analysis efforts for key UAV subsystems across the entire product lifecycle: concept, prototyping, testing, production, and field support.
• Develop innovative, manufacturable airframe designs optimized for UAV flight performance under varying operational conditions, ensuring structural, dynamic, thermal and functional requirements are met through rigorous analysis and validation.
• Analyze initial aerostructure designs against preliminary mass properties targets and strength and stiffness requirements.
• Create and maintain high-quality 3D CAD models, detailed engineering drawings, and manufacturing documentation using SolidWorks, emphasizing GD&T principles to ensure precision and manufacturability.
• Lead the structural mechanical design of aircraft primary and secondary structures in the airframe, from initial concept through production.
• Develop and champion innovative structural solutions to optimize weight, cost, and performance, often taking the lead on these efforts.
• Develop structural requirements, specifications, and test plans (DVP&R) with minimal guidance.
• Review of static & dynamic load inputs, material properties and test results.
• Independently perform analyses using FEA and hand calculations to predict performance under various loading conditions (static, dynamic, fatigue, etc.).
• Lead and oversee structural testing, expertly analyze test data, and take ownership of generating detailed test reports.
• Proactively investigate and resolve complex structural issues that arise during development and providing robust design solutions.
• Contribute to the development and improvement of structural analysis methodologies and best practices within the team.
• Drive high-cadence iterative design and analysis cycles, supporting rapid prototyping and cross-functional design reviews to incorporate test feedback promptly and continuously improve hardware through agile development processes.
• Collaborate cross-functionally with electrical engineers, flight-test engineers, and manufacturing teams to integrate complex mechanical and electromechanical systems, including servos, pumps, sensors, cameras, PCBAs, wiring harnesses, and connectors.
• Support technical reviews and contribute to design and analysis decisions, ensuring robust engineering practices and adherence to program requirements.
• Support rapid prototyping efforts with hands-on experience building functional prototypes in a shop environment, iterating designs based on real-world results and test data.
• Troubleshoot mechanical and electromechanical issues through root cause anal