Senior Product Engineer

Position Summary

Flight Wave, a wholly owned subsidiary of Red Cat Holdings, is seeking a Senior Product Engineer to serve as the critical bridge between design intent and production reality. In this role, you will own the product definition and ensure our unmanned drone platforms transition seamlessly from engineering design to repeatable, high‑quality manufacturing. You will work at the intersection of Design Engineering, Manufacturing, Supply Chain, and Quality—translating innovative designs into manufacturable products that meet our performance, quality, and cost objectives.

• Partner with the Design Engineering team to ensure manufacturable designs are released, providing DFM expertise throughout the product development cycle
• Review and approve engineering designs across multiple drone platforms, ensuring compatibility with manufacturing processes including composite layup, 3D printing, injection molding, PCB assembly, electromechanical assembly, and motor integration
• Conduct design reviews and provide technical feedback to prevent downstream manufacturing and quality issues
• Drive design improvements that reduce cost, improve quality, and enhance manufacturability

• Contribute the product definition in Solid Works and Arena PLM, ensuring complete and accurate documentation
• Manage all Engineering Change Order (ECO) activity for assigned products, coordinating cross‑functional review and implementation
• Ensure BOMs, drawings, assembly instructions, and specifications are complete, accurate, and manufacturing‑ready
• Maintain configuration control and product data integrity throughout the product lifecycle

• Coordinate and lead first article builds, working hands‑on with manufacturing team to validate designs and processes
• Identify and resolve manufacturing issues during prototyping and production ramp
• Develop and refine assembly processes, tooling requirements, and work instructions
• Support qualification testing and certification activities

• Serve as the primary technical interface between Design Engineering, Manufacturing Engineering, Supply Chain, and Quality
• Work closely with Manufacturing Engineers to optimize production processes and resolve technical issues
• Partner with Supply Chain to evaluate supplier capabilities, support vendor selection, and resolve component‑related issues
• Collaborate with Quality team to address non‑conformances, implement corrective actions, and drive continuous improvement

• Identify opportunities to improve product quality, reduce manufacturing costs, and streamline production processes
• Lead root cause analysis and corrective action for product‑related issues
• Drive standardization and best practices across product platforms

• Bachelor's degree in Mechanical Engineering, Aerospace Engineering, Manufacturing Engineering, or related field
• 7+ years of product engineering or manufacturing engineering experience, preferably in aerospace, defense, or high‑reliability electromechanical products
• Proven track record of successfully transitioning complex products from design to production
• Proficiency in Solid Works (3D modeling, drawing creation, assemblies)
• Experience with Arena PLM or similar PLM systems
• Strong understanding of manufacturing processes
• Deep knowledge of GD&T, tolerance analysis, and design for assembly
• Familiarity with aerospace quality standards and practices

• Bachelor’s degree in Engineering
• Experience with unmanned aerial systems (UAS) or drone technology
• Knowledge of AS9100 or similar aerospace quality management systems
• Experience with FAA regulations and certification processes for unmanned aircraft
• Background in New Product Introduction (NPI) processes
• Six Sigma or Lean Manufacturing certification

• Ability to lift 50lbs
• Standing for long periods of time
• Ability to work in different environments and heat

This position will require successfully completing a post‑offer background check.…