Mechanical Engineer III/IV

At Zone 5 Technologies, we're redefining what's possible in unmanned aircraft systems. Our team of engineers and innovators is developing cutting-edge autonomous solutions that push the boundaries of UAS technology - solving complex challenges that matter.

We're building the future of UAS capabilities, and we're looking for exceptional talent to join us. If you're driven by hard problems, energized by rapid innovation, and ready to make an impact on next-generation flight systems, you belong here.

We're looking for an experienced Mechanical Engineer for unmanned aircraft systems (UAS) is responsible for the design, development, and optimization of mechanical systems for unmanned aerial vehicles (UAVs) and other aerospace applications. This role focuses on creating innovative and reliable mechanical components for UAVs, ensuring their structural integrity, performance, and compliance with industry standards. The engineer will work with cross-functional teams to advance UAS technologies in sectors such as defense, commercial aviation, and space exploration.

Responsibilities:

• Design and Development: Design mechanical components and systems for UAVs and other aerospace vehicles, including airframes, propulsion systems, control surfaces, landing gears, and payload integration.
• Prototyping and Testing: Build and test UAV prototypes to ensure mechanical reliability and performance, including ground and flight tests to validate designs.
• Structural Analysis: Conduct stress, strain, and fatigue analysis on UAV structures and systems to ensure they can withstand operational conditions such as high speeds, altitudes, and varying temperatures.
• Thermal Management: Design and analyze thermal systems to manage heat dissipation, especially for high-performance UAVs and aerospace applications.
• System Integration: Collaborate with electrical, avionics, and software engineers to integrate mechanical systems with sensors, communication, and control systems in unmanned aircraft.
• Material Selection: Evaluate and select lightweight, high-performance materials for UAVs, optimizing for fuel efficiency, durability, and strength.
• Failure Analysis: Perform root cause analysis on mechanical system failures and develop solutions to enhance the safety and performance of UAVs.
• UAV Maintenance and Repair Procedures: Develop guidelines for the inspection, maintenance, and repair of UAV mechanical systems to ensure long- term operational efficiency.
• Regulatory Compliance: Ensure all designs meet relevant UAS regulations and industry standards.
• Engage in R&D for cutting-edge UAS technologies, including autonomous systems, additive manufacturing, and advanced composite materials. 
• Documentation: Create detailed reports, design specifications, maintenance manuals, and testing documentation for UAS mechanical systems. 

Qualifications: 

• Education: Bachelor's or Master's degree in Mechanical Engineering, Aerospace Engineering, or a related field.
• Experience: 3-7 years of experience in aerospace mechanical systems, including 2+ years working on unmanned aircraft (UAVs) or related autonomous systems.

Skills:

• Proficiency in CAD and mechanical design software (e.g., SolidWorks) for aerospace and UAS applications.
• Proficiency in detailed design including geometric dimensioning and tolerancing (GD&T) and drafting.
• Experience with design for manufacturability (DFM) and tooling design. 
• Experience with finite element analysis (FEA) 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-specific regulations and broader aerospace certification processes (e.g., DO-160, AS9100).
• Strong analytical, problem-solving, and project management skills.

Pay range for this role

$120,000 - $160,000 USD

What's in it for you:

Benefits: 

• Competitive total compensation package 
• Comprehensive benefit package options include medical, dental, vision, life, and more.
• 401k with company-match 
• 4 weeks of paid time off each year
• 12 annual company holidays

Why Join Zone 5 Technologies?

• Innovative Environment: Work on cutting-edge technology that is shaping the future of defense and aerospace.
• Collaborative Culture: Join a team of passionate professionals dedicated to pushing the boundaries of what's possible.
• Career Growth: Opportunities for professional development and career advancement.

If you are passionate about unmanned aircraft technology and want to be a part of a dynamic and growing company, we would love to hear from you. Apply today and join the Zone 5 Technologies team 

Note about our Texas roles: we are in the process of opening a location on the mid-west side of the DFW metro region. Roles in Texas will initially work remotely and then be expected to be onsite when that location opens in 2026.

In compliance with federal law, all persons hired will be required to verify identity and eligibility to work in the United States and to complete the required employment eligibility verification form upon hire.

Zone 5 Technologies is a federal contractor and participates in E-Verify to confirm employment eligibility. As required by law, we will verify the identity and employment authorization of all new employees using the E-Verify system. Learn more about your rights and responsibilities under E-Verify: https://www.e-