Mechanical Design & Analysis Engineer

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. Firestorm is seeking a highly skilled Mechanical Design & Analysis Engineer to join our innovative engineering team in developing next-generation UAV systems. As a Mechanical Design & Analysis 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. About The Role In this role, you will play a pivotal role in developing mechanical components and subsystems that satisfy demanding criteria for performance, manufacturability, and cost. Your expertise will bridge advanced aerospace technology and practical engineering as you collaborate cross-functionally with electrical, manufacturing, and flight-test teams to ensure seamless integration of mechanical and electromechanical systems. What You’ll Do Support 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 mechanical designs optimized for UAV flight performance under varying operational conditions, ensuring structural, thermal, and functional requirements are met through rigorous analysis and validation. 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. Validate and optimize designs using a combination of hand calculations, finite element analysis (FEA), mission-level simulations (e.g., MATLAB, Simulink), and physical testing. 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 analysis and implement effective corrective actions. Contribute to configuration management and documentation control, maintaining clear versioning of CAD files, assemblies, and design revisions. Build and maintain engineering rigor by contributing to the development of company-wide best practices, including CAD standards, documentation protocols, and hardware management processes. Support Design for Manufacturability (DFM) efforts, working closely with internal and external manufacturing teams to refine parts and processes—including additive manufacturing, CNC machining, sheet metal, injection molding, and composite tooling and fixturing. Leverage additive manufacturing and traditional fabrication methods to produce high-performance UAV components. Required Qualifications Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, or a related discipline. 3+ years of mechanical design experience, working directly with aircraft design. Minimum 1 year of hands-on experience in structural analysis. Strong foundation in mechanical engineering fundamentals; structures, fluid systems, thermal management, and mechanisms. Hands-on design engineering experience, with proven application of design-for-manufacturability (DFM) principles. Experience analyzing primary and secondary aircraft structures using industry-standard tools and methods. Demonstrated ability to perform structural modeling and analysis of mechanical components and assemblies. Proficiency in first-order structural analysis and hand calculations, including free body diagrams, statics, and mechanics of materials. Experience in SolidWorks, including surfacing, top-down design, and advanced modeling techniques, plus strong knowledge of GD&T principles. Experience integrating mechanical designs with electrical systems, including PCBAs, wiring harnesses, and electromechanical components such as servos and sensors. Direct application of DFM and designing for additive, traditional, and composite manufacturing methods, including tooling and fixturing for composite assemblies. Must be a U.S. Person (citizen or permanent resident) and able to work on-site in San Diego. Preferred Qualifications 5+ years’ of professional mechanical design experience, working directly with aircraft design, and analysis 3+ of hands-on experience in structural analysis. Hands-on experience with UAV or aerospace flight structures, including knowledge of rotary and fixed-wing platforms. Proven ability to develop and execute mission-level simulations or analysis tools using MATLAB, Simulink, or similar environments Background supporting the full hardware development lifecycle, including design, prototyping, testing, and production Demonstrated skill in correlating analytical results with physical test data and applying findings to improve design performance Familiarity with configuration management, version control practices for CAD, and engineering documentation control Familiarity with designing injection-molded components or polymer-based additive manufacturing techniques. Work Environment Based at our Headquarters in San Diego, CA This role requires an on-site presence Must be able to lift up to 30 lbs. and wear appropriate PPE [as required] Willingness to travel up to 10% domestically for testing and demonstrations Ability to work flexible hours and travel to various testing locations as needed Compensation US Salary Range: $92,000 - $146,000 USD Benefits & Perks We offer comprehensive medical, dental, and visions plans 401(k) Retirement Savings Plan to invest in your long-term retirement goals Equity grants for new hires Unlimited PTO Extremely generous company holiday calendar, including a holiday hiatus in November, & December. Generous Parental Leave Lifestyle Spending Account FSA DCFSA HSA Hospital Indemnity insurance Critical Illness insurance Accident insurance Basic Life/AD&D, short-term and long-term disability insurance, 100% covered by Firestorm. Equal Opportunity Statement Firestorm is an equal opportunity employer, committed to creating a diverse and inclusive workplace, and upholding equitable hiring practices. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, disability, protected veteran status, or any other characteristic under federal, state, or local law.

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