Senior Mechanical Design Engineer | Aerospace & Autonomous Systems

Senior Mechanical Design Engineer | Aerospace & Autonomous Systems

Chicago (Schaumburg), IL

Full-time | Open 6/29/26 | Close 7/13/26

Wing Xpand is Expanding What’s Possible with Autonomous Systems, building long‑endurance, backpackable smart plane drones and robotics systems that support defense, public safety, disaster response, and commercial missions. Our platforms operate across air, ground, and maritime domains, integrating autonomy, AI‑powered sensing, edge computing, and networked systems to deliver real‑world intelligence and threat detection. We design, build, and deploy complete systems—hardware, software, and data—and we move fast.

As Wing Xpand scales, we are seeking high performers to grow with our team.

Wing Xpand is building the future of autonomous systems. We are seeking a Senior Mechanical Design Engineer to help invent, design, and build the aircraft and mechanical systems behind our next generation robotic platforms. This is a hands‑on engineering role for builders who want to own meaningful work, solve difficult problems, and see their designs fly. You will lead the design of robotic structures, mechanisms, payload integrations, and production hardware that directly shape the performance of our systems.

You will work alongside exceptional aerospace, robotics, software, electrical, and manufacturing engineers to rapidly turn ideas into flight‑ready products through design, prototyping, testing, and continuous iteration. This is a place for engineers who thrive on ownership, move with urgency, embrace ambitious challenges, and care deeply about building products that support those protecting and serving others. If you are looking a standard corporate job, this is not the role for you.

If you want to do the most meaningful work of your career alongside other high performers, we would love to meet you.

• Design and develop robotic structures and mechanical systems for Wing Xpand's autonomous platforms
• Design lightweight airframes, mechanisms, payload integrations, and electromechanical assemblies
• Develop robust, manufacturable designs using composites, metals, plastics, and additive manufacturing
• Create production ready CAD models, engineering drawings, and manufacturing documentation
• Perform structural analysis, tolerance analysis, and engineering trade studies
• Prototype, assemble, test, and validate hardware through laboratory and flight testing
• Collaborate closely with aerospace, robotics, electrical, software, and manufacturing engineers
• Rapidly troubleshoot, improve, and optimize mechanical designs through testing and field feedback
• Drive engineering decisions from concept through production
• Help shape the next generation of Wing Xpand products

• Bachelor's degree in Mechanical Engineering, Aerospace Engineering, or a related field
• 7+ years of professional experience designing complex mechanical or aerospace systems
• Expertise with Solid Works or equivalent professional CAD software
• Experience designing products from concept through prototype, testing, and production
• Strong understanding of manufacturing processes, mechanical design, GD&T, and engineering fundamentals
• Comfortable building, testing, troubleshooting, and improving physical hardware
• Self motivated with a bias for action and a willingness to own challenging technical problems

• Master's degree in a relevant field
• Experience designing UAV, aerospace, robotics, or autonomous systems
• Experience with composite structures and lightweight design
• Experience with finite element analysis
• Experience designing for CNC machining, additive manufacturing, injection molding, or sheet metal fabrication
• Experience supporting production and manufacturing
• Experience participating in flight testing or field operations

To conform to U.S. Government aerospace technology export regulations, applicant must be a 'U.S. Person' (U.S. Citizen or a Permanent Resident/Green Card Holder).

If you are a self‑motivated, results‑driven individual with a passion for innovation and technology, we want to hear from you!