Aero-Mechanical Engineer

Summary of Position:

The Aero-Mechanical Engineer is a key contributor to aerospace product development and manufacturing at Zepher Flight by leading product design projects from research and concept generation through design, development, prototyping, testing, market launch, manufacturing, and sustainment. Additionally, he/she is responsible for making recommendations on new technologies and identifying areas of opportunity for new products based on in depth knowledge of the market and customer needs that align with the strategic objectives of the business. He/she is expected to develop innovative solutions and perform advanced design work requiring extensive engineering knowledge and skills. He/she is responsible for project management of fabrication builds in his/her area of focus, including communication regarding technical aspects of projects to customers. Further, he/she is a major hands-on contributor to overall product build, fabrication, and integration efforts alongside technicians and other team members.

Essential Duties and Responsibilities:

Reporting to the Chief Engineer, the Aero-Mechanical Engineer shall have/perform:

• Regular and proactive collaboration with the rest of the team
• Bachelor's degree in aerospace or mechanical engineering, or extensive UAV experience with other 4-year engineering degree, or other similar experience.
• Aerospace and defense industry experience desirable.
• Large breadth of engineering knowledge with an emphasis on unmanned aircraft design, prototyping, and test.
• Mechanical and structural integration of airborne payloads and new subsystems, for example a SATCOM system or SAR payload.
• Knowledge and experience with 3D printing methods, materials and best practices desirable
• 5 or more years of experience in UAV design and development desirable.
• Advanced interpersonal skills, along with the ability to communicate effectively and maintain credibility with customers, suppliers, and across all coworkers within the business.
• Excellent problem solving and analytical skills; demonstrated passion for building and operating aircraft, solving problems, and operational excellence.
• Strong writing, organizational and communication skills.
• Expert SolidWorks operator with professional training a minimum of 2 years of frequent use.
• Performing aerodynamic analysis of UAV fuselages, wings, and tails using both spreadsheet-based methods and CFD.
• Mass properties analysis. This includes prediction of component weights, tracking of component weights, and calculation of aircraft mass properties at all times.
• Acoustic analysis and designing vehicle parts to meet acoustic objectives. This primarily relates to the acoustics of propellers and electric motors, but also relates to all sources of vehicle noise.
• Structural design and optimization of carbon fiber parts desired. Primary building method is prepreg carbon molded with hard tooling. Other methods such as RTM, VARTM, compression, and conventional bagging may also be used.
• Lead design projects with accountability for meeting all parameters including cost, schedule and performance targets.
• Contribute to advancement of the product development process.
• Lead as-built configuration documentation and system architecture definition for use in ZFL electronic systems.
• Lead efforts to transition products from prototyping into initial production. Advance manufacturing readiness.
• Develop two dimensional drawings and design specification documentation, establish test plan/procedures, and develop and deliver design review packages, as required.
• Develop and present project data as required by company and customer reporting requirements.
• Develop procedures and work instructions for the technical work performed in his/her area of responsibility.
• Contribute to the creation, modification, and maintenance of all documents, procedures, contracts, risk management plans, and any other documentation required by a customer, stakeholder, or the Zepher Flight organization.
• High level of proficiency with technology including Microsoft Office.
• Strong teaching and learning skills
• Bias toward taking initiative and proactively solving problems within their area of responsibility
• Physical activities can include standing, walking, lifting, pushing or carrying heavy objects, sitting for long periods of time, keyboarding, other computer and desk work, auto and plane travel
• Other duties as assigned

Preferred Qualifications:

• Understanding of advanced heat transfer and management
• Understanding EMI best practices relative to mechanical and structural design and material choices
• Expertise in 3D printing methods, materials and best practices
• Understanding of the “Mod Payload” design standard
• Understanding of various flight management systems
• Model aircraft and/or helicopter experience desirable.
• Hands-on experience building, prototyping, and testing complex unmanned systems
• Direct experience in transitioning new products from prototyping into production.

This position may require access to information that is subject to compliance with the International Traffic in Arms Regulations (ITAR) and/or the Export Administration Regulations (EAR). To conform to the requirements of the ITAR and/or the EAR, applicant must be a U.S. citizen, lawful permanent resident of the U.S., or protected individual as defined by 8 U.S.C. 1324b(a)(3).

Zepher Flight Labs is an equal opportunity employer. Qualified candidates will be considered for employment regardless of race, color, religion, age, sex, (including pregnancy and gender identity), sexual orientation, political affiliation, national origin, marital status, medical condition, disability, genetic information, parental status, military or Veteran status.