Senior Mechanical Engineer

Position Summary

We are seeking a technically rigorous Senior Mechanical Engineer to join a multidisciplinary defense engineering team developing autonomous maritime and airborne systems. This role spans the full engineering lifecycle — from rapid concept prototyping through production-quality design, test execution, and fielding support — in direct support of U.S. Navy and other defense programs.

The successful candidate will bring deep technical grounding in core mechanical engineering disciplines (mechanics of materials, fluid dynamics, thermodynamics and heat transfer), hands-on experience with advanced manufacturing equipment and composite fabrication, and practical familiarity with defense acquisition processes and Systems Engineering best practices.

Essential Duties and Responsibilities

Structural & Mechanical Design

• Design mechanical systems and structures to meet operational requirements with clearly documented and verified safety factors adequate for sustained military use
• Apply mechanics of materials principles — stress, strain, fatigue, fracture mechanics, and failure mode analysis — to all structural designs
• Perform FEA and analytical hand calculations to validate designs prior to fabrication; iterate rapidly based on results
• Produce engineering drawings, GD&T specifications, and design documentation compliant with defense acquisition standards

Rapid Prototyping & Manufacturing

• Execute rapid design-build-test cycles to quickly evaluate concepts and reduce integration risk before committing to production-quality solutions
• Operate and program CNC mills, waterjets, and 5-axis laser systems; manage toolpaths and setup for complex geometry parts
• Design, lay up, and cure composite structures using traditional wet lay-up, Resin Transfer Molding (RTM), and Vacuum-Assisted Resin Transfer Molding (VaRTM) processes
• Specify fiber architectures, core materials, resin systems, and cure cycles to meet structural, thermal, and weight requirements
• Support DfM studies and tolerance analyses using GD&T and SolidWorks or equivalent CAD tools

Fluids, Thermal & Propulsion Analysis

• Apply fluid dynamics to internal and external flow problems including hydrodynamic loading, drag reduction, and hydraulic system design
• Conduct thermodynamic and heat transfer analyses to ensure thermal margins are maintained across operating environments, including shock, vibration, and submersion
• Support design of thermal management systems for electronics, actuators, and propulsion subsystems in maritime and airborne platforms

Test & Field Support

• Plan and execute System Integration Lab (SIL) and Hardware-in-the-Loop (HIL) test campaigns; develop test procedures, collect and analyze data, and produce test reports
• Deploy to field environments in support of Navy, Air Force, and joint military exercises and operational demonstrations
• Support instrumentation setup including strain gauges, accelerometers, load cells, and environmental sensors; calibrate and validate measurement systems
• Author and review test documentation (TEMP, test plans, test reports) in compliance with DoD 5000 series acquisition standards

Systems Engineering

• Apply MBSE frameworks to decompose operational requirements into system architectures, interfaces, subsystem specifications, and design behaviors
• Author and maintain Systems Engineering documentation including SEPs, ICDs, ECPs, CDRLs, and configuration management records
• Identify and manage technical risk through structured FMEA, reliability analysis, and design review processes
• Liaise across software, autonomy, electrical, and systems teams to resolve integration conflicts and maintain design coherence
• Support configuration control processes through standard CM tools; manage ECPs and PECPs through design change lifecycle

Required Qualifications

• Candidates must meet one of the following thresholds:
  • Ph.D. in Mechanical Engineering with 5 years of relevant professional experience
  • M.S. in Mechanical Engineering with 7-10 years of relevant professional experience
  • B.S. in Mechanical Engineering field with 10 years of relevant professional experience
• Demonstrated mastery of mechanics of materials: stress analysis, fatigue, fracture, failure modes, and selection of appropriate safety factors for operational use
• Demonstrated mastery of fluid dynamics: internal and external flows, hydrodynamic loading, CFD interpretation, and hydraulic system design
• Demonstrated mastery of thermodynamics and heat transfer: conduction, convection, radiation, thermal management system design, and environmental qualification
• Direct hands-on experience with CNC machining, waterjet cutting, additive manufacturing techniques, and 5-axis laser systems — including setup, fixturing, and toolpath programming
• Direct experience fabricating composite structures via at least two of: traditional wet lay-up, RTM, and/or VaRTM processes
• Proficiency in 3D CAD (SolidWorks, CATIA, or equivalent) with GD&T drawing production
• Familiarity with FEA tools (ANSYS, NASTRAN, or equivalent) for structural and thermal analysis
• Experience supporting military or Government testing or exercises in a direct technical role
• Working knowledge of Systems Engineering best practices and documentation in the aerospace or defense sector
• Active U.S. Secret clearance (or ability to obtain)

Additional Desired Qualifications

• Experience with autonomous maritime systems (USV, UUV, AUV) or autonomous airborne systems (UAS, cruise missiles)
• Experience with MBSE tools such as Cameo Systems Modeler or equivalent
• Familiarity with PID control system integration and SIL/HIL test environments
• Experience with sonar, radar, EO/IR, ordnance, or other defense sensor payloads
• Active TS/SCI clearance
• Experience applying ITAR, DoD 5000, MOSA/WOSA, or AS9100/ISO9001 compliance requirements
• Publication record or demonstrated subject matter expertise in a relevant technical discipline

Physical Requirements and Working Conditions

• Must be able to walk, stand, and navigate large indoor and outdoor facilities for extended periods of time.
• Ability to lift, carry, and move materials and equipment weighing up to 25 lbs on a regular basis.
• Use of personal protective equipment (PPE) may be required in designated areas or when performing specific tasks, in accordance with safety protocols and company policy.
• May be required to climb ladders, stoop, kneel, or crouch during inspections, maintenance walk-throughs, or emergency response situations.
• Regular exposure to facility operations including noise, dust, temperature fluctuations, and industrial equipment.
• Occasional off-hours or weekend work required for emergency facility responses or projects as needed
• Requires frequent use of a computer and other standard office equipment for documentation, communication, and coordination tasks.

Background Check

This position will require successfully completing a post-offer background check. Qualified candidates with a criminal history will be considered and are not automatically disqualified, consistent with federal and state law.

EEO and ITAR/EAR Work Authorization Disclosure

Red Cat Holdings provides equal employment opportunities (EEO) to all employees and applicants for employment and prohibits discrimination and harassment of any type without regard to race, color, religion, age, sex, national origin, disability status, genetics, protected veteran status, sexual orientation, gender identity or expression, or any other characteristic protected by federal, state or local laws. This position requires direct or indirect access to hardware, software, technology or technical data controlled under the International Traffic in Arms Regulations (ITAR) and the Export Administration Regulations (EAR). Successful candidates for positions subject to ITAR/EAR restrictions must provide proof of U.S. Citizenship or Permanent Residence and must not require sponsorship for export-restricted work authorization.

E-Verify

The company participates E-Verify ensure eligibility for employment and compliance with Right to Work rules.

Compensation: Base pay, plus generous annual equity package and potential bonuses.