Mechanical Engineer III​/IV

Overview

At Zone 5 Technologies, we are redefining unmanned aircraft systems with autonomous solutions that push the boundaries of UAS technology. We are seeking an experienced Mechanical Engineer for unmanned aircraft systems (UAS) to design, develop, and optimize mechanical systems for UAVs and other aerospace applications, ensuring structural integrity, performance, and regulatory compliance. The engineer will collaborate with cross-functional teams to advance UAS technologies in defense, commercial aviation, and space exploration.

• Design mechanical components and systems for UAVs and aerospace vehicles, including airframes, propulsion systems, control surfaces, landing gears, and payload integration.
• Prototype and test UAVs to validate mechanical reliability and performance, including ground and flight tests.
• Conduct structural analysis (stress, strain, fatigue) to ensure UAV structures withstand operational conditions such as high speeds, altitudes, and temperature variations.
• Design and analyze thermal management systems to dissipate heat in high-performance UAVs and aerospace applications.
• Collaborate with electrical, avionics, and software engineers to integrate mechanical systems with sensors, communications, and control systems.
• Select lightweight, high-performance materials optimizing for fuel efficiency, durability, and strength.
• Perform root-cause analysis on mechanical failures and develop solutions to improve safety and performance.
• Develop UAV maintenance and repair procedures to ensure long-term operational efficiency.
• Ensure designs meet relevant UAS regulations and industry standards.
• Engage in R&D for autonomous systems, additive manufacturing, and advanced composite materials.
• Prepare detailed reports, design specifications, maintenance manuals, and testing documentation for UAS mechanical systems.

• Education:
  
  Bachelor’s or Master’s degree in Mechanical Engineering, Aerospace Engineering, or related field.
• Experience:
  
  3-7 years in aerospace mechanical systems, including 2+ years on UAVs or related autonomous systems.

• Proficiency in CAD and mechanical design software (e.g., Solid Works) for aerospace/UAS.
• Strong knowledge of geometric dimensioning and tolerancing (GD&T) and drafting.
• Experience with design for manufacturability (DFM) and tooling design.
• Experience with finite element analysis (FEA), computational fluid dynamics (CFD), and other 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 regulations and aerospace certification processes (e.g., DO-160, AS9100).
• Strong analytical, problem-solving, and project management skills.

Pay range: $120,000 - $160,000 USD

• Comprehensive benefit package options including medical, dental, vision, life, and more.
• 401(k) with company match
• 4 weeks of paid time off per year
• 12 annual company holidays

• Innovative Environment:
  Work on cutting-edge technology shaping the future of defense and aerospace.
• Collaborative Culture: A team dedicated to pushing the boundaries of what’s possible.
• Career Growth:
  Opportunities for professional development and advancement.

If you are passionate about unmanned aircraft technology and want to join a dynamic and growing company, apply today to join Zone 5 Technologies.

Note about our Texas roles: We are opening a location on the mid-west side of the Dallas–Fort Worth metro region. Roles in Texas will initially work remotely and then be onsite when the location opens in 2026.

In compliance with federal law, all hires must verify identity and eligibility to work in the United States and complete the required employment eligibility verification upon hire. Zone 5 Technologies is a federal contractor and participates in E-Verify. Details about E-Verify and employee rights are available at the U.S. Department of Homeland Security/E-Verify and (Use the "Apply for this Job" box below)..

Equal Employment Opportunity:
Zone 5 Technologies does not discriminate on the basis of protected status. Public burden statement and voluntary self-identification forms are included as part of compliance requirements.