Mechanical Engineer - UAS

T3i Inc.•San Antonio, TX

8h•Onsite

About The Position

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. 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.

Requirements

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

Nice To Haves

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

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)