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Mechanical Engineer - UAS

T3i Inc.•San Antonio, TX
•Onsite
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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)

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What This Job Offers

Job Type

Part-time

Career Level

Mid Level

Education Level

No Education Listed

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