Mechanical Engineer - UAS at T3i Inc.

San Antonio, Texas, United States -

Full Time

Start Date

Immediate

Expiry Date

23 Jul, 26

Salary

0.0

Posted On

24 Apr, 26

Experience

2 year(s) or above

Remote Job

Yes

Telecommute

Yes

Sponsor Visa

Skills

Mechanical design, CAD, SolidWorks, FEA, Structural analysis, Composite materials, CNC machining, GD&T, ASME Y14.5, Drone systems, Propulsion integration, Vibration isolation, Mass properties analysis, DFM/DFA, MIL-STD-810, Rapid prototyping

Industry

Defense and Space Manufacturing

Description

Job Summary: T3i builds mission-critical unmanned systems designed to improve US forces operational and lethal capabilities on the battlefield. Our Blackfoot platform is a tactical FPV drone system engineered for reliability, adaptability, and rapid deployment. We operate in tight feedback loops between design, build, and field use, where hardware decisions directly impact mission outcomes. We are a small, fast-moving team that values ownership, technical depth, and execution. We're looking for a Mechanical Engineer (ME) to support the mechanical architecture of our drone systems, from concept through production. The ME will design, fabricate, test, and iterate on complete mechanical systems including airframes, propulsion integration, payload bays, and structural hardware. The ME will work hands-on in the shop, in integration, and during flight testing, closing the loop between design intent and real-world performance. Position Summary: The ME will be responsible for the design, integration, testing, and continuous improvement of the mechanical systems supporting the Blackfoot platform. This role emphasizes hands-on development, rapid iteration, and system-level ownership across the full hardware lifecycle. The ideal candidate thrives in fast-paced environments, is comfortable working across mechanical and electrical boundaries, and contributes to building reliable, field-ready systems. Primary Responsibilities: * Support mechanical design across airframe, motor mounts, payload bays, & landing systems * Design and fabricate multi-component assemblies for high-performance drone platforms * Perform structural and FEA analysis to validate designs under flight, loads, and crash * Select and specify materials including CFRP composites, aluminum alloys, and engineering plastics for weight-critical applications * Integrate propulsion system components including motor mounts, ESC thermal management, and propeller clearance envelopes * Conduct mass properties analysis (CG, MOI) and coordinate with flight systems team to maintain acceptable flight dynamics * Design vibration isolation solutions to protect sensitive electronics (IMU, cameras, RF systems) on propeller-driven airframes * Develop and maintain technical drawings with GD&T callouts per ASME Y14.5 standards * Build, test, and iterate hardware rapidly using real-world feedback from flight operations * Support MIL-STD-810 environmental testing (shock, vibration, temperature, humidity) and implement design improvements * Coordinate mechanical/electrical interface design including wiring harness routing, connector placement, and PCB mounting provisions * Drive designs from prototype through production (DFM/DFA, BOM, & build documentation) Minimum Qualifications: * 3 years of hands-on mechanical engineering experience * Proven experience designing and fabricating real hardware systems * Strong CAD proficiency (SolidWorks preferred; CATIA, Fusion 360, or NX accepted) * Demonstrated FEA experience (SolidWorks Simulation, ANSYS, or Abaqus) * Working knowledge of GD&T per ASME Y14.5 * Experience with lightweight structural materials including CFRP composites or aluminum alloys * Familiarity with DFM/DFA and hands-on prototype fabrication (CNC machining, FDM, SLA) * Understanding of rotating propulsion system mechanics, vibration, and dynamic loading * Ability to work independently and take ownership of ambiguous design problems Preferred Qualifications: * Hands-on experience building, repairing, or flying FPV or tactical UAS platforms * Familiarity with MIL-STD-810 test methods and environmental qualification requirements * Experience with mass properties management and CG/MOI analysis for UAS platforms * Knowledge of battery mechanical integration and thermal management in UAS airframes * Experience coordinating with external machine shops or composite fabricators * SolidWorks CSWA or CSWP certification * Familiarity with payload integration for ISR or EW systems on tactical UxS * Experience working in fast-paced R&D or defense environments Clearance Requirements: None required (must be a U.S. Person eligible to work on ITAR-controlled programs) Required Background Check: HireRight background check & drug screening Type of Employment: Part-Time (with potential to transition to full time) T3i Drug Free Workplace Statement: As a Federal Government Contractor, T3i is required to strictly adhere to federally mandated drug-free workplace standards. To ensure compliance with this requirement, T3i conducts pre-employment drug screening for all new hire personnel (full time, part time, and independent contractor) and annual random drug screening for all current T3i personnel. Personnel who cannot pass drug screening are not eligible for employment with T3i.

Responsibilities

The Mechanical Engineer will design, fabricate, and test drone systems, including airframes and propulsion integration, from concept through production. They will work hands-on in the shop and during flight testing to iterate on hardware based on real-world performance.