Lead Aerospace Engineer

Modalic builds AI-powered swarm motherships for autonomous long-range strike and sensing for the US and our Allies.

We are driven by a single challenge: unlock the potential of attritable swarms. Small drones are limited by their range, payload capacity, and computational power. We are giving autonomous swarming drones near infinite reach, putting an end to this paradigm.

Modalic was founded by experts in autonomous systems and multi-domain intelligence. Our team rapidly delivers critical technology to our national security users.

As an early Modalic employee, you will get to help decide the direction of our future. We are looking for a Lead Aerospace Engineer to head our aerospace engineering efforts for a composite, fixed‑wing Group 3 UAS. With support of the wider team and the design/prototyping/manufacturing efforts already underway, you will own aircraft configuration, airframe structures, aero/performance, and propulsion‑airframe integration from concept through flight test and production.

• Own aircraft configuration and requirements for a composite fixed‑wing Group 3 UAS: execute trades across aerodynamics, structures, propulsion, mission systems, cost, and manufacturability; maintain weight, CG, and performance budgets.
• Lead composite airframe design (wing, fuselage, tail, control surfaces): ply‑level laminate design, sandwich panel construction, bonded joints/adhesives, metallic‑composite interfaces, repairability, and quality considerations.
• Drive detailed CAD models of aerospace and mechanical systems.
• Plan and perform structural analysis (FEA): linear/nonlinear static, buckling, modal, and fatigue; correlate with hand calcs and flight/ground test data; close margins and document substantiation.
• Own aerodynamics & CFD: conceptual and preliminary aero design, stability & control, performance estimation, propeller slipstream/airframe interaction, cooling‑flow and inlet/outlet analyses; set loads for structural sizing.
• Integrate a heavy‑fuel piston‑prop system: mounts and vibration isolation, torque/gyroscopic load paths, cooling, intake/exhaust, fuel systems, and propeller selection/performance matching to mission.
• Define and execute ground & flight test plans for structures and aero/performance (static load, vibration, environmental), instrument articles, and drive root‑cause/containment on test findings; apply relevant environmental/qualification practices (e.g., DO‑160/MIL‑STD‑type testing).
• Design for manufacture & rate production: own processes, vacuum bagging best practices, cure cycles, tooling strategy, and quality/inspection gates; collaborate tightly with manufacturing and suppliers.
• Collaborate cross‑functionally (autonomy/GNC, avionics, propulsion, test, supply chain) to deliver aircraft that are rugged, lightweight, field‑maintainable, and mission‑ready; support prototype builds and flight operations.
• Participate in the full development lifecycle, from concept and design through verification, validation, and transition to production; continuously improve standards, checklists, and design guides for the aerospace function.

• BS in Aerospace Engineering, Mechanical Engineering, or related field.
• 3 years of professional experience in composite aircraft design and autonomous systems.
• Proven experience in CFD and aero analysis for fixed‑wing aircraft including performance, stability & control, prop/airframe interactions.
• Structural analysis (FEA) experience for composites: laminate theory, allowables/margins, linear & nonlinear, buckling, modal, fatigue; ability to reconcile analysis with test/flight data.
• Strong CAD proficiency (e.g., Fusion 360, PTC Creo).
• Hands‑on composites knowledge: layup, vacuum bagging, cure processes, bonded assemblies, and composites DFM best practices.
• Experience working with / integrating piston and turboprop engines on small-to-midsize UAS (mounts, vibration/loads, cooling/induction, exhaust, fuel).
• Proficiency with engineering documentation (requirements, analyses, test plans/reports) and version control practices.
• Experience supporting ground/flight testing and troubleshooting in field conditions.
• Excellent cross‑functional collaboration and communication skills; ability to “own” a subsystem from concept to delivery.
• Expert understanding of aerodynamic theory and dynamic loading scenarios.
• Solid understanding of Aviation industry, aviation history, and DoD standards.
• Familiarity with validating aerospace systems during flight test events or operational environments.
• Hands-on experience supporting flight demos or live exercises.
• Eligible to obtain and maintain an active U.S. Secret security clearance.

• MS or PhD in Aerospace Engineering, Mechanical Engineering, or related field.
• 10 years of professional experience in autonomous systems.
• Advanced CFD experience for propeller slipstream and cooling flows.
• Advanced FEA & analysis toolchain experience including dynamic response, contact, and progressive failure approaches; proficiency correlating models to test.
• Deep composite expertise: cured‑part dimensional control, bonded joint design/analysis, and damage tolerance/repair.
• Experience with power plant-to‑airframe integration for heavy‑fuel piston and turboprop systems: engine selection/trades, prop matching, vibration/isolation, thermal management, and fuel system layout.
• Qualification experience with environmental/structural testing consistent with aerospace practices (e.g., DO‑160‑style and/or MIL‑STD‑style testing).
• Manufacturing scale‑up exposure: tooling strategy, production readiness, close collaboration with manufacturing & supply chain.
• Systems integration experience working with autonomy/GNC, avionics, payloads, and propulsion to deliver rugged, fieldable aircraft; proven support for prototype integration and flight test.
• Experience in aircraft systems engineering and owning system-level processes such as requirements, mass budgets, power budgets.

In compliance with International Traffic Arms Regulations (ITAR), candidates must be U.S. Citizens, U.S. Permanent Residents (Green Card holders) or individuals granted asylee/refugee status as defined by 8 U.S.C. 1324b(a)(3).

We are committed to being an equal opportunity employer. We encourage applications from all individuals, regardless of race, color, religion, sex, sexual orientation, gender identity, national origin, veteran status, or disability.