Senior Mechanical Engineer

RED CAT HOLDINGS•Salt Lake City, UT

2d•Onsite

About The Position

Apium Swarm Robotics (ASR) is revolutionizing swarm autonomy software for air, surface, undersea, and ground vehicles operating across dual-use commercial and defense environments. Our systems are deployed on real platforms, tested in the field, and delivered to customers operating in complex, uncertain, and safety-critical conditions. We do not build research prototypes or slideware. Our software is integrated into real vehicles, tested in the field, and delivered to customers who depend on operational reliability, speed of execution, and mission relevance. We prioritize performance over hype. ASR systems represent the next phase in autonomy: collaborative swarming. These are not like pre-programmed drones for light shows. We are creating real-time cooperative management that lets one operator control dozens to hundreds of vehicles in real-time with the ease of controlling a single vehicle. As such, this role requires comfort with responsibility, ambiguity, and operational accountability. ASR seeks a mechanical engineer to join our hardware development team. This role targets a designer and builder capable of owning the full lifecycle of physical hardware — from concept through manufacture — across a range of enclosure, packaging, and drone integration products. Primary responsibilities include the design and manufacture of Dongle Cases and Bridge Boxes, the ruggedized electronic enclosures central to ASR’s ground station and communications infrastructure. Unlike many hardware roles, ASR’s compact swarm platform allows mechanical work to be prototyped and iterated quickly, with in-house 3D printing and a bias toward rapid, field-testable designs. Travel may be required for field testing and demonstrations which will allow you to witness firsthand how your hardware performs as dozens of drones take flight. Position will also encompass the design, testing, and manufacture of drone attachments and physical modifications — ranging from simple mounting brackets to complex multi-axis actuators — as well as the development of mechanisms supporting ASR’s “swarm in a box” concept: self-contained, rapidly deployable swarm systems with integrated logistics, charging, and launch capability. The role includes responsibility for ASR’s swarm packaging program: specifying, sourcing, and customizing Pelican case configurations and precision-cut foam inserts to ensure vehicles and ground equipment survive transport and deployment in demanding field environments.

Requirements

Proficiency in 3D CAD modeling software (SolidWorks, Fusion 360, or equivalent)
Hands-on experience with FDM and/or resin 3D printing, including material selection and print optimization
Practical knowledge of 3D printing materials including PLA, PETG, ABS, TPU, Nylon, and composite variants
Experience building, flying, or modifying UAVs and familiarity with drone hardware ecosystems
Understanding of robotics mechanisms including servo and stepper motor integration, linkages, and motion systems
Industrial design competency including IP/ingress protection ratings, vibration tolerance, thermal management, and impact resistance
Basic understanding of LiPo and lithium-ion battery systems, charging architectures, and associated safety considerations
Experience designing enclosures and hardware for field deployment, including considerations for sealing, ingress protection, and structural durability
Ability to work effectively within a cross-functional team alongside software, electrical, and systems engineers
Comfort working independently with limited oversight
Ability to remain calm and effective under operational pressure

Nice To Haves

BS in Mechanical Engineering or related field
Experience with injection molding, vacuum forming, or other production-scale manufacturing processes
Experience with CNC machining, laser cutting, or other subtractive and precision fabrication methods
Familiarity with MIL-SPEC, MIL-STD-810, or equivalent environmental qualification standards
Experience with EMI/RFI shielding considerations in enclosure design
Experience specifying and working with custom foam fabrication, including CNC-cut foam inserts for equipment cases
Experience with FPV racing, custom drone builds, or UAS competition platforms
Basic electronics knowledge sufficient to collaborate on PCB mounting, connector selection, and wire routing within enclosures
Experience with GD&T (Geometric Dimensioning and Tolerancing) and tolerance stack-up analysis
Familiarity with pneumatic, hydraulic, or cable-driven actuation systems
Experience with finite element analysis (FEA) or computational fluid dynamics (CFD) tools
Previous experience supporting hardware programs in defense, aerospace, or other safety-critical environments
Strong mechanical, electrical, or systems troubleshooting skills
U.S. security clearance or ability to obtain one

Responsibilities

Design and oversee manufacture of Dongle Cases, Bridge Boxes, and other ruggedized electronic enclosures
Specify, source, and customize swarm packaging solutions including Pelican cases and precision foam inserts
Design, test, and manufacture drone attachments and physical modifications, from simple brackets to actuated mechanisms
Collaborate with the engineering team on “swarm in a box” mechanism design, prototyping, and field validation