{"id":746129,"url":"https://alion.io/job/elroyair-mechanical-engineer-mechanical-systems","title":"Mechanical Engineer - Mechanical Systems","company":{"id":673892,"name":"Elroy Air","domain":"elroyair.com","url":"https://alion.io/company/elroyair","size_band":"51-200","is_staffing_agency":false,"employer_type":"direct","is_intermediary":false,"listed_via":null,"ats_vendor":"Lever","truth_index":{"grade":"B","score":75,"open_postings":5,"ghost_share":0,"stale_share":1,"repost_share":0,"time_to_fill_p50_days":null,"computed_at":"2026-10-29T05:49:05Z"}},"role":"Industrial Engineering","role_family":"Industrial Engineering","seniority":"senior","employment_type":"full_time","work_mode":"hybrid","remote_scope":null,"remote_scope_basis":null,"remote_working_hours":null,"hiring_geo_confidence":"structured","locations":["Byron, United States"],"countries":["US"],"hiring_countries":[],"hiring_countries_total":0,"salary":{"min":120000,"max":222000,"currency":"USD","period":"year","gross":null,"usd_annual":222000},"salary_estimate":null,"experience_years_min":5,"visa_sponsorship":false,"relocation_package":false,"has_equity":true,"technologies":[{"name":"ANSYS","optional":false},{"name":"CATIA","optional":false},{"name":"Femap","optional":false},{"name":"GD&T","optional":false},{"name":"Nastran","optional":false},{"name":"SolidWorks","optional":false},{"name":"MATLAB","optional":true},{"name":"Python","optional":true}],"status":"live","first_seen_at":"2023-12-21T00:38:44Z","employer_posted_date":"2023-12-21","last_verified_at":"2026-10-29T05:09:58Z","board_verified":true,"closed_at":null,"days_open":1043,"trust":{"level":"stale","repost_count":0,"flags":["stale"],"days_open":1043},"description":"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.\nWhat you’ll own:\nDesigning 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\n\nApply first-principles analysis, FEA, trade studies, and engineering best practices to ensure components and assemblies meet load, weight, and safety requirements for flight\n\nDefine subsystem and component requirements compatible with safety, performance, and program objectives; manage functional and physical interfaces between subsystems and the vehicle\n\nSelect materials appropriate for aerospace applications (aluminum alloys, titanium, composites) with consideration for weight, strength, fatigue, and manufacturability\n\nApply DFM principles across fabrication methods including composites, sheet metal, machining, 3D printing, welding, and bonding to support efficient, producible designs\n\nConduct environmental analysis and testing, including vibration, shock, thermal, and corrosion, and support design and build of test fixtures to verify subsystem performance and safety\n\nSelect and manage suppliers and partners to ensure components are delivered within budget, schedule, and specification\n\nPrepare and present at gated design reviews to demonstrate design adequacy\n\nOur ideal candidate:\nB.S. in Mechanical Engineering, Aerospace Engineering, or a related discipline; M.S. preferred\n\n5+ years of hands-on experience as a professional mechanical engineer, directly related to vehicle subsystem design in the automotive, aeronautical, or space industries\n\nProficiency with SolidWorks and/or CATIA, including PDM/PLM and data release processes\n\nProficiency with MBD and GD&T (ASME Y14.5)\n\nExperience with FEA tools (NASTRAN, ANSYS, FEMAP, or similar) for structural and thermal analysis\n\nStrong grasp of materials selection for aerospace applications: aluminum alloys, titanium, composites, and their relevant specifications and failure modes\n\nExperience with vibration, shock, thermal, and corrosion environmental testing and analysis\n\nFluency in first-principles, hand, and computer-aided analysis to guide and substantiate mechanical designs\n\nWorking knowledge of aerospace production processes and DFM trade-offs across composites, sheet metal, machining, 3D printing, welding, and bonding\n\nBonus points for:\nExperience with lift+cruise, tiltrotor, or other eVTOL platforms\n\nPrior design, fabrication, test, and operation of airworthy primary/secondary structures, flight control surface and actuation systems, rotors and propellers, payload handling systems, landing gear, or thermal management systems\n\nExperience developing components for weight-constrained applications\n\nProficiency with FEMAP, NX Nastran, MATLAB, Mathcad, LabVIEW, and/or Python\n\nWorking knowledge of FAA Part 21 type certification processes and Part 23/Part 27 airworthiness standards, including means and methods of compliance\n\nWhat we offer:\nCompetitive salary\nEquity ownership in a rapidly growing advanced aerospace company\nComprehensive medical benefits\n401(k) with company contribution + Roth IRA\nFree daily lunch provided onsite\nFlexible time-off policy\n3 months of paid parental leave\nEmployee assistance program with 24/7 support\nHigh-impact startup environment with significant ownership and autonomy\nOpportunities for rapid career growth and internal advancement\nYou’ll work with a motivated, kind, and highly skilled team\nYou'll help shape and define our company culture and values\nYou'll help build and scale a new category of aerospace / logistics 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