Senior Staff Airframe Design 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 Senior Staff Airframe Design Engineer to join our innovative engineering team in developing next-generation UAV systems. As a Senior Staff Airframe Design Engineer at Firestorm, you will be responsible for the design 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. 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. In order to be successful in this role, you must be someone who is self-motivated, adaptable and is able to lead your own projects to completion in a fast-paced environment. Ideally, you have significant structural airframe design experience and a proven track record completing collaborative projects effectively. A successful candidate will have proven experience delivering high-performance, mass-optimized hardware in rapid development environments, with a strong foundation aircraft mechanical design. Proficiency in 3D CAD and first-order hand calculation 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 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. Develop structural requirements, specifications, and test plans (DVP&R). Review of static & dynamic load inputs, material properties and test results. Lead and oversee structural testing, expertly analyze test data, and take ownership of generating detailed test reports.