Senior Hardware Product Packaging Engineer

Skydio is the leading US drone company and the world leader in autonomous flight, the key technology for the future of drones and aerial mobility. The Skydio team combines deep expertise in artificial intelligence, best-in-class hardware and software product development, operational excellence, and customer obsession to empower a broader, more diverse audience of drone users, from utility inspectors to first responders, soldiers in battlefield scenarios, and beyond.

Packaging is the first thing a customer sees and touches and the last mile between our hardware and our customers. A Skydio drone might ship across the country in a corrugated carton, live for three years in a hard case in the trunk of a patrol car, get thrown in the back of a utility truck, or be carried into the field on a soldier’s back — and it has to work every time it comes out.

You will own the designs that make that workflow possible: the unboxing moment, the field case, the foam, the labeling, and the pack-out on our production line. This is a highly cross-functional role sitting between design, manufacturing, supply chain, and our vendors.

• Own customer-facing and enterprise-ready packaging from concept to mass production across Skydio’s full product ecosystem including aircraft, docks, controllers, batteries, attachments, and accessories. You will lead the design and execution of commercial cartons, ruggedized field and transit cases, precision foam and molded-fiber inserts, multi-component kits, and accessory trays.
• Design packaging parts and assemblies in 3D CAD, including cushion geometry, cavity fits, trays, closures, and case interiors, with die lines and drawings that a vendor can build.
• Partner with industrial design, product management, and marketing to craft an unboxing and use experience worthy of the product inside
• Engage with mechanical, electrical, battery and material flow engineering to keep product safe and improve transport efficiency
• Interface with and own technical activity at vendors in partnership with operations and supply chain teams — RFQs, tooling kickoffs, first article inspection, quality and inspection criteria, and corrective action when parts come in wrong packaging, working closely with the Supplier Quality Engineers and Product Quality Teams.
• Design for a broad set of packaging processes and make the call on which one fits: corrugated and folding carton, molded fiber, thermoforming, rotational and injection molding, converted and CNC-routed foams, and soft goods. Work with Material Flow and Logistics to optimize packaging sizes and dunnage for spatial and operational gains
• Define and execute transit and field testing including drop, vibration, compression, incline impact, thermal and humidity conditioning against some or all of ISTA, ASTM D4169, ATA 300, and MIL-STD-810 as appropriate, and use analysis to prove the design before you cut tooling.
• Own packaging compliance and labeling: lithium battery shipping marks and documentation, hazmat and carrier requirements, regulatory markings, serialization, and the artwork process that keeps them all correct across SKUs and regions.
• Support our internal manufacturing and factory teams with pack-out processes, line-side layout, packaging BOMs, and work instructions that hold up at rate.
• Debug field damage and shipping returns with an eye for the smallest details and a commitment to reach the deepest causes.

• Prior packaging or product development experience with a proven track record of execution, enthusiasm, and cooperation. This role could be a senior-level depending on experience.
• Bachelor’s degree in mechanical engineering, packaging engineering, or equivalent with demonstrated…