Mechanical Engineer III/IV

Position Overview

At Zone 5 Technologies, we're redefining what's possible in unmanned aircraft systems. Our team of engineers and innovators is developing cutting-edge autonomous solutions that push the boundaries of UAS technology – solving complex challenges that matter.

We are seeking an experienced Mechanical Engineer for unmanned aircraft systems. In this role, you will design, develop, and optimize mechanical systems for UAVs and other aerospace applications. You’ll collaborate with cross-functional teams to ensure structural integrity, performance, and regulatory compliance while advancing next-generation flight systems.

Compensation: $120,000 - $160,000 USD

Key Responsibilities

• Design mechanical components and systems for UAVs and aerospace vehicles, including airframes, propulsion systems, control surfaces, landing gears, and payload integration.
• Build and test UAV prototypes to ensure mechanical reliability and performance through ground and flight tests.
• Conduct stress, strain, and fatigue analysis on UAV structures to verify their ability to withstand operational conditions.
• Design and analyze thermal systems to effectively manage heat dissipation for high-performance UAVs.
• Collaborate with electrical, avionics, and software engineers to integrate mechanical systems with sensors, communication, and control technologies.
• Evaluate and select lightweight, high-performance materials to optimize fuel efficiency, durability, and strength.
• Perform root cause analysis on mechanical failures and develop solutions to enhance safety and performance.
• Develop guidelines for the inspection, maintenance, and repair of UAV mechanical systems to ensure long-term operational efficiency.
• Ensure all designs comply with relevant UAS regulations and industry standards.
• Engage in R&D for cutting-edge UAS technologies, including autonomous systems and advanced composite materials.
• Create detailed reports, design specifications, maintenance manuals, and testing documentation.

Required Qualifications

• Education: Bachelor's or Master's degree in Mechanical Engineering, Aerospace Engineering, or a related field.
• Experience: 3-7 years in aerospace mechanical systems, including 2+ years on unmanned aircraft (UAVs) or related autonomous systems.
• Proficiency in CAD and mechanical design software (e.g., SolidWorks) for aerospace and UAS applications.
• Expertise in detailed design including geometric dimensioning and tolerancing (GD&T) and drafting.
• Experience with design for manufacturability (DFM), tooling design, and finite element analysis (FEA) using simulation tools.
• Strong knowledge of fluid dynamics, thermodynamics, structural mechanics, and aerodynamics.
• Understanding of UAV manufacturing processes, including 3D printing and advanced composite materials.
• Familiarity with UAV-specific regulations and broader aerospace certification processes (e.g., DO-160, AS9100).
• Strong analytical, problem-solving, and project management skills.

Benefits & Perks

• Competitive total compensation package
• Comprehensive benefit package including medical, dental, vision, life insurance, and more.
• 401k with company-match
• 4 weeks of paid time off each year
• 12 annual company holidays