{"id":2561068,"url":"https://alion.io/job/applied-intuition-mechanical-engineer-drone","title":"Senior Mechanical Engineer, Drone","company":{"id":5396,"name":"Applied Intuition","domain":"appliedintuition.com","url":"https://alion.io/company/applied-intuition","size_band":"1001-5000","is_staffing_agency":false,"employer_type":"direct","is_intermediary":false,"listed_via":null,"ats_vendor":"Ashby","truth_index":{"grade":"B","score":77,"open_postings":106,"ghost_share":0.009,"stale_share":0.877,"repost_share":0.019,"time_to_fill_p50_days":53,"computed_at":"2026-10-21T05:46:15Z"}},"role":"Industrial Engineering","role_family":"Industrial Engineering","seniority":"senior","employment_type":"full_time","work_mode":"on_site","remote_scope":null,"remote_scope_basis":null,"remote_working_hours":null,"hiring_geo_confidence":"structured","locations":["Sunnyvale, United States"],"countries":["US"],"hiring_countries":[],"hiring_countries_total":0,"salary":{"min":170000,"max":260000,"currency":"USD","period":"year","gross":null,"usd_annual":260000},"salary_estimate":null,"experience_years_min":10,"visa_sponsorship":false,"relocation_package":false,"has_equity":false,"technologies":[{"name":"Physical AI","optional":false},{"name":"SolidWorks","optional":false}],"status":"live","first_seen_at":"2026-10-14T18:34:22Z","employer_posted_date":"2026-10-14","last_verified_at":"2026-10-21T10:03:57Z","board_verified":true,"closed_at":null,"days_open":6,"trust":{"level":"ok","repost_count":null,"flags":[],"days_open":6},"description":"Applied Intuition, Inc. is powering the future of physical AI. Founded in 2017 and now valued at $15 billion, the Silicon Valley company is creating the digital infrastructure needed to bring intelligence to every moving machine on the planet. Applied Intuition services the automotive, defense, trucking, construction, mining and agriculture industries in three core areas: tools and infrastructure, operating systems, and autonomy. Eighteen of the top 20 global automakers, as well as the United States military and its allies, trust the company’s solutions to deliver physical intelligence. Applied Intuition is headquartered in Sunnyvale, California, with offices in Washington, D.C.; San Diego; Ft. Walton Beach, Florida; Ann Arbor, Michigan; London; Stuttgart; Munich; Stockholm; Bangalore; Seoul; and Tokyo. Learn more at applied.co.\nWe are an in-office company, and our expectation is that full-time employees primarily work from their Applied Intuition office 5 days a week. However, we also recognize the importance of flexibility and trust our employees to manage their schedules responsibly. This may include occasional remote work, starting the day with morning meetings from home before heading to the office, or leaving earlier when needed to accommodate family commitments. This in-office expectation does not apply to contractor positions\nAbout the role\nAs a Senior Mechanical Engineer on our drone program, you will help figure out how to make our aircraft fly: designing the airframe, structures, and mechanical systems that let our autonomy take to the air. You will be part of the full product design lifecycle, from concept and prototype through flight test and production, and your work will directly shape how our uncrewed aircraft perform. You will design lightweight, durable hardware, build it, fly it, break it, and make it better.\nAt Applied Intuition, you will:\nOwn the mechanical design of our drone platforms, including airframe, fuselage, wings or rotor arms, landing gear, and structural components\n\nMake the tradeoffs between weight, strength, aerodynamics, flight time, and payload capacity that determine whether an aircraft flies well\n\nIntegrate propulsion, batteries, avionics, and payloads into the airframe, including packaging, mounting, cooling, and cable routing\n\nPerform structural, thermal, and vibration analysis, and use flight and test data to validate and improve the design\n\nPrototype quickly: build, assemble, and iterate on real hardware, and support flight testing and field operations\n\nAnalyze failures and crashes, drive root cause, and turn lessons into design improvements\n\nOwn the design, analysis, and validation at the component, assembly, and fully integrated aircraft level\n\nDesign for manufacturability, repairability, and field serviceability\n\nWork cross-functionally with autonomy, avionics, electrical, software, and flight test teams to make sure designs meet mission requirements\n\nWe're looking for someone who has:\nBS or MS in Mechanical Engineering, Aerospace Engineering, or a related field\n\n10+ years of experience designing hardware and shipping products, ideally for drones, UAS, or aircraft\n\nHands-on experience designing flight vehicles or flight-critical structures, such as airframes, wings, fuselages, rotor arms, or landing gear\n\nStrong understanding of what makes an aircraft fly: weight, structures, aerodynamic loads, stability, and propulsion integration\n\nExperience designing lightweight structures, including composites, carbon fiber, and aerospace-grade metals\n\nExperience with design for manufacturing across methods such as CNC machining, composite layup, sheet metal, and additive manufacturing\n\nProficiency in CAD, SolidWorks preferred, for 3D design and modification\n\nHands-on prototyping and fabrication skills, and comfort building and testing real aircraft\n\nNice to have:\nAbility to support flight test and field operations, including setting up devices under test, running test scripts from test engineers, and writing clear documentation for test, maintenance, safety, and team processes\n\nExperience designing, drawing, and prototyping custom cable harnesses\n\nDemonstrated experience in FEA/CAE (structural, thermal, vibration, and shock)\n\nDon’t meet every single requirement? If you’re excited about this role but your past experience doesn’t align perfectly with every qualification in the job description, we encourage you to apply anyway. You may be just the right candidate for this or other roles.\nApplied Intuition is an equal opportunity employer and federal contractor or subcontractor. Consequently, the parties agree that, as applicable, they will abide by the requirements of 41 CFR 60-1.4(a), 41 CFR 60-300.5(a) and 41 CFR 60-741.5(a) and that these laws are incorporated herein by reference. These regulations prohibit discrimination against qualified individuals based on their status as protected veterans or individuals with disabilities, and prohibit discrimination against all individuals based on their race, color, religion, sex, sexual orientation, gender identity or national origin. These regulations require that covered prime contractors and subcontractors take affirmative action to employ and advance in employment individuals without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, protected veteran status or disability. The parties also agree that, as applicable, they will abide by the requirements of Executive Order 13496 (29 CFR Part 471, Appendix A to Subpart A), relating to the notice of employee rights under federal labor laws.\nFOR US-BASED ROLES:Applied Intuition is committed to providing an accessible and inclusive application and interview experience to applicants who are disabled veterans and other applicants with disabilities or medical conditions. Reasonable accommodations are available, requesting an accommodation will not affect your candidacy in any way, and you are not required to disclose the nature of your disability or medical condition in order to make a request. If you require an accommodation please contact . 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