Senior Mechanical Design Engineer
Firestorm
Design
San Diego, CA, USA
USD 140k-170k / year
Posted on May 31, 2025
Senior Mechanical Design Engineer
San Diego, CA
Engineering
In office
Full-time
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. This person will be responsible for critical flight structures and mechanism design and build efforts for Firestorm's product line. The Senior Mechanical Engineer will work closely with a fast-moving team of peers and engineering leadership to ensure mission-critical hardware is delivered on time and meets demanding technical performance.
In this role, you’ll play a critical part in designing mechanical components and subsystems that meet demanding performance, manufacturability, and cost goals. You’ll work at the intersection of advanced aerospace technology and practical engineering—collaborating closely with electrical, manufacturing, and flight-test teams to ensure seamless integration of mechanical and electromechanical systems.
A successful candidate will have significant experience delivering high-performance, mass-constrained hardware in a rapid development environment. Your expertise in 3D CAD, precision mechanical design, and system-level integration will be instrumental in driving forward novel solutions that expand the capabilities of our UAV platforms. As a senior-level individual contributor, you’ll have deep ownership over the technical direction of your designs and play a key role in shaping engineering best practices across projects. You’ll be involved in all phases of the development cycle—from early concept and prototyping to rigorous testing and production—in a fast-paced, high-impact environment.
What You’ll Do
- Own mechanical design 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.
- 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 hand calculations, finite element analysis (FEA), and physical testing.
- Drive high-cadence iterative design cycles, supporting rapid prototyping and leading 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.
- Lead technical reviews and contribute to design 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. Write detailed build documentation and collaborate hands-on with technicians during hardware integration and assembly.
- Support 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.
- Assist in project scheduling and resource coordination to ensure timely delivery of engineering milestones.
- Provide informal mentorship and technical guidance to junior engineers, fostering a culture of engineering excellence.
Required Qualifications
- Bachelor’s degree in Mechanical Engineering or a related discipline.
- 7+ years of mechanical design experience with full product lifecycle ownership, preferably within the aerospace or UAV industry.
- Hands-on design engineering experience, with proven application of design-for-manufacturability (DFM) principles.
- Demonstrated technical leadership across multiple projects or complex systems.
- Deep expertise in SolidWorks, including surfacing, top-down design, and advanced modeling techniques, plus strong knowledge of GD&T principles.
- Strong foundation in mechanical engineering fundamentals—structures, fluid systems, thermal management, and mechanisms.
- Experience integrating mechanical designs with electrical systems, including PCBAs, wiring harnesses, and electromechanical components such as servos and sensors.
- Extensive experience in DFM and designing for additive, traditional, and composite manufacturing methods, including tooling and fixturing for composite assemblies.
- Proficient in designing fluid systems, including pumps, valves, tubing, and connectors.
- Must be a U.S. Person (citizen or permanent resident) and able to work on-site in San Diego.
Preferred Qualifications
- Experience with UAV or aircraft systems, including knowledge of rotary- and fixed-wing platforms.
- Hands-on experience operating, maintaining, or troubleshooting UAVs.
- Familiarity with electrical wiring practices and AC/DC power systems.
- Working knowledge of communication protocols such as CAN, Ethernet/IP, and Serial.
- Experience with configuration management practices for CAD and documentation control.
- Familiarity with designing injection-molded components or polymer-based additive manufacturing techniques.
Work Environment
This role is onsite at our headquarters in San Diego.
Compensation
US Salary Range: $140,000 - $170,000 USD
The posted salary range reflects an estimate based on a variety of compensation factors, including but not limited to relevant experience, education, certifications, specialized skills, geographic location, and business needs. Actual compensation may vary, and this range is subject to change as our compensation structure or market conditions evolve.
Benefits & Perks
Our culture fosters collaboration, respect, and trust, empowering passionate people to do their best work. We offer a competitive salary, comprehensive benefits, and opportunities for career growth. In addition to an opportunity to take part in an innovative, collaborative and fast-growing business with a highly motivated and skilled team, we also take pride in taking care of our employees. Here are just a few ways that we show our appreciation:
- We offer comprehensive medical, dental, and visions plans
- 401(k) Retirement Savings Plan to invest in your long-term retirement goals
- Unlimited PTO
- Generous Parental Leave
- FSA
- HSA
- Hospital Indemnity insurance
- Critical Illness insurance
- Accident insurance
- Basic Life/AD&D, short-term and long-term disability insurance, 100% covered by Firestorm. Plus, the option to purchase additional life insurance for you and your family.
- Mental Health Resources: We provide free mental health resources 24/7 including therapy and more. Additional work-life services, such as free legal and financial support, are available to you as well.
ITAR Compliance
To conform to U.S. Government space technology export regulations, including the International Traffic in Arms Regulations (ITAR) you must be a U.S. citizen, lawful permanent resident of the U.S., protected individual as defined by 8 U.S.C. 1324b(a)(3), or otherwise eligible to obtain the required authorizations from the U.S. Department of State.
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, including those with a criminal history, in a manner consistent with the requirements of applicable state and local laws, including the CA Fair Chance Initiative for Hiring Ordinance. We actively encourage members of recognized minorities, women, Veterans, and those with disabilities to apply, and we work to create a welcoming and supportive environment for all applicants throughout the interview process.
Firestorm is committed to fostering an inclusive and accessible work environment. If you require accommodations or assistance during the application process, please don’t hesitate to reach out to us at [email protected] so we can provide the support you need.
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Req ID: R32
