Senior Mechanical Engineer at Firestorm in San Diego, CA

Job description

Who We Are At Firestorm, we are building the future of expeditionary defense manufacturing and autonomous systems. Modern conflict has exposed a fundamental problem: the systems needed most by operators are often too expensive, too slow to produce, and too difficult to sustain at scale. Firestorm exists to change that. We develop mission-adaptable aerial systems and deployable manufacturing infrastructure designed to put capability directly into the hands of the warfighter. From modular unmanned aircraft to xCell — our deployable microfactory — our goal is to make defense systems rapidly deployable, adaptable, and producible at the point of need. We are looking for builders, operators, and problem-solvers who want to work on meaningful technology with real-world impact. About the Role 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. You will work closely with a dynamic and fast-paced team of engineers and leadership to ensure mission-critical hardware meets stringent technical, schedule, and performance requirements. 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. 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 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. Analyze initial aerostructures 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. Validate and optimize designs using a combination of hand calculations, finite element analysis (FEA), 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 progra