Mechanical Engineer - Mechanical Systems

As a Mechanical Engineer at Elroy Air, you will be responsible for owning the design, analysis, build, and test of the flight-critical mechanical systems that bring our autonomous cargo UAV to life.

You will work on a range of mechanical and structural systems, driving mechanical design and decision making that enables aircraft testing and flight.

• Designing and developing vehicle subsystems, including primary and secondary structures, flight control surfaces and actuation systems, landing gear, and thermal management systems from architecture definition through integration
• Apply first-principles analysis, FEA, trade studies, and engineering best practices to ensure components and assemblies meet load, weight, and safety requirements for flight
• Define subsystem and component requirements compatible with safety, performance, and program objectives; manage functional and physical interfaces between subsystems and the vehicle
• Select materials appropriate for aerospace applications (aluminum alloys, titanium, composites) with consideration for weight, strength, fatigue, and manufacturability
• Apply DFM principles across fabrication methods including composites, sheet metal, machining, 3D printing, welding, and bonding to support efficient, producible designs
• Conduct environmental analysis and testing, including vibration, shock, thermal, and corrosion, and support design and build of test fixtures to verify subsystem performance and safety
• Select and manage suppliers and partners to ensure components are delivered within budget, schedule, and specification
• Prepare and present at gated design reviews to demonstrate design adequacy
• B.S. in Mechanical Engineering, Aerospace Engineering, or a related discipline; M.S. preferred
• 5+ years of hands-on experience as a professional mechanical engineer, directly related to vehicle subsystem design in the automotive, aeronautical, or space industries
• Proficiency with SolidWorks and/or CATIA, including PDM/PLM and data release processes
• Proficiency with MBD and GD&T (ASME Y14.5)
• Experience with FEA tools (NASTRAN, ANSYS, FEMAP, or similar) for structural and thermal analysis
• Strong grasp of materials selection for aerospace applications: aluminum alloys, titanium, composites, and their relevant specifications and failure modes