Senior Aero Mechanical Engineer

Redwire Defense Tech•Ottawa, ON

6d•$115,000 - $135,000•Onsite

About The Position

The Senior Aero-Mechanical Engineer is responsible for the design, development, and validation of complex mechanical systems and subsystems for uncrewed aerial systems (UAS). This role emphasizes practical, hands-on engineering over purely analytical or simulation-focused work. The engineer independently owns major subsystem designs—balancing performance, reliability, and manufacturability—and contributes to broader system architecture through technical input and design reviews. The Senior Engineer plays a key role during prototype builds, test campaigns, and production transitions, helping resolve issues and drive designs to completion. They are recognized for their expertise in mechanical design and cross-functional coordination, improving designs through iteration and testing and refining designs based on real-world performance. This is a hands-on engineering role in a small, fast-moving team. You will be expected to take ownership of small to medium mechanical design projects and carry them from concept through to prototype, test, and iteration. Work is highly practical and execution-focused. A typical week might include CAD design, 3D printing or machining parts, assembling hardware, and testing systems in the lab or field. We are not a large, process-heavy organization. Engineers are expected to be self-directed, comfortable working with incomplete requirements, and motivated to build and try ideas quickly. Projects often involve early-stage concepts where requirements are evolving and creativity is required. You enjoy building real hardware and seeing your designs work in practice. You are comfortable working across the full lifecycle of a product—design, fabrication, assembly, and testing—and prefer hands-on problem solving over purely analytical work. Strong candidates will be able to point to projects they have personally built or significantly contributed to. You are curious and proactive, capable of making progress when requirements are not fully defined. You are not waiting for detailed specifications—you are helping to discover what the right solution should be. This role is well suited for engineers with experience in personal, academic, or professional projects involving robotics, UAVs, vehicles, or other electromechanical systems. This role is not primarily focused on analysis-only work or highly specialized modeling. Candidates seeking roles centered on simulation, research, or narrowly scoped analysis may find this position is not the best fit.

Requirements

Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, or a related field required.
4–7 years of relevant experience in mechanical or aerospace engineering, with demonstrated ownership of major subsystems or assemblies.
Comfortable working in hands-on fast-paced development environments where design, fabrication, and testing are closely integrated.
Track record of building and iterating on physical projects, either personal projects or team-based engineering challenges (e.g., robotics teams, UAVs, vehicles).
Advanced proficiency with CAD modeling and drafting (SolidWorks preferred).
Hands-on familiarity with rapid prototyping tools (e.g., 3D printers, small CNC machines) and test activities.
Working knowledge of materials, composites, machined parts, and structural integration.
Hands-on experience designing, fabricating, and assembling mechanical systems.
Strong technical judgment and decision-making skills.
Excellent communication and collaboration across multi-disciplinary teams.
Analytical mindset with strong problem-solving and root-cause analysis capabilities.
Organized and detail-oriented with experience managing multiple design tasks simultaneously.
Ability to mentor others and uphold engineering rigor and design quality.
Ability to pass a background check.
Ability to be insured by the Company’s Auto-policy.
Ability to obtain a Top-Secret Clearance.

Nice To Haves

6–8 years of demonstrated involvement in hands-on engineering projects (e.g., UAVs, robotics, vehicles, or similar systems) for aerospace, defense, or similarly regulated environments.
Track record of leading subsystem integration efforts and participating in flight or environmental testing.
Ability to make progress with incomplete requirements and iterate toward practical solutions.
Background in prototyping, fabrication, or small-batch production.
Strong working knowledge of advanced analysis tools (FEA, CFD, or fatigue analysis) and interpreting results for design optimization.
Deep understanding of GD&T, mechanical drawing standards, and documentation control.
Experience developing and reviewing engineering standards or process documentation.
Familiarity with PDM/PLM systems (e.g., SolidWorks PDM, Windchill).
Strong presence with the ability to influence technical direction.
Ability to synthesize feedback from multiple stakeholders into actionable design decisions.
Continuous improvement mindset, with a focus on efficiency and repeatable design excellence.
Comfort operating in fast-paced environments with evolving program requirements.

Responsibilities

Own the design, modeling, and analysis of major mechanical and structural subsystems for UAS.
Perform and review tolerance analysis, structural analysis (FEA), and materials selection.
Design and fabricate prototype components using rapid prototyping methods (e.g., 3D printing, CNC machining).
Support hands-on build, integration, and modification of hardware systems during development and testing.
Oversee design documentation, drawing release, and configuration management activities.
Iterate on designs based on test results, field feedback, and evolving requirements.
Collaborate with cross-functional teams (mechanical, electrical, and software) to ensure cohesive system integration.
Support prototype builds, resolving issues related to manufacturability, fit, and performance.
Develop and execute test plans to validate structural integrity and system performance.
Participate in and contribute to design reviews (CoDR, PDR, CDR), incorporating feedback into designs.
Support production readiness and quality verification for new and existing products.
Mentor junior engineers and CAD specialists, promoting technical best practices and efficient workflows.
Contribute to continuous improvement initiatives in design standards, configuration management, and documentation processes.