Mechanical Engineer - Enclosure Design
Confirmed on the employer's own hiring board on Oct 2, 2026. First seen by Alion on Sep 16, 2026.
Swarm Aero is redefining air power, building the largest swarming UAV and the most versatile swarming aircraft network in the world. The company is moving quickly to launch the first aircraft designed specifically for swarming, as well as the Command & Control software to mobilize swarms of thousands of heterogeneous autonomous assets and empower human operators to achieve superhuman results.
The team has created and exited multiple startups, negotiated defense deals worth billions of dollars, and designed and built 30+ novel aircraft, with aerospace experience from Scaled Composites, Airbus, Archer Aviation, Blue Origin, and Boom Supersonic.
Swarm Aero is building autonomous UAV swarms that operate in contested environments where the electrical and avionics systems have to work every time. We need an engineer with experience designing electronics enclosures and structure for harsh environments. An engineer who can cross boundaries and work with all subsystems through avionics design, integration, and validation.
What You'll Do
Design and develop aircraft avionics enclosures and secondary structure, including analysis and test of your designs
Work with the mechanical team to integrate avionics devices into the airframe by specifying or creating necessary mounts and brackets
Assist in the definition and implementation of mechanical design standards and requirements for avionics enclosures
Develop and maintain mechanical models, drawings, and ICDs using appropriate design tools
Collaborate with suppliers to implement DFM practices to improve manufacturability, cost, and lead-time
Support flight test anomaly investigation and drive root cause analysis on avionics faults related to mechanical systems
Contribute to airworthiness documentation and flight authorization packages
What We're Looking For
3+ years of enclosure design experience on aerospace, defense, UAS platforms, or similar industries with harsh environments
Strong familiarity with aerospace mechanical design standards and the ability to communicate design intent following ASME 14.5 GD&T
Proficiency with CAD tools such as NX, Solidworks/Catia, CreoParametric, or equivalent
Experience designing with various materials such as aluminum, copper, polymers, composites, or similar
Experience designing for various metal shaping processes such as CNC machining, laser cutting, waterjet, bending, stamping, or similar
Experience with various coatings and sealants such as paint, plating, chemical conversion, or similar
Experience taking components and systems from design through hardware integration and test
US person status required; active security clearance a plus
Nice to Have
Experience specifically on UAS or unmanned aircraft programs
Experience with electrical harness design, routing, and integration
Experience with DO160, MIL-STD-810, and/or related environmental test standards
Familiarity with MIL-STD-461 testing, EMI/EMC analysis and mitigation on flight vehicles
Exposure to defense programs or military airworthiness processes
Sheet-metal or composites design experience (professional or hobby)
PCB design or embedded electronics background (professional or hobby)
Scripting experience
ITAR requirement
To conform to U.S. Government export regulations, applicant must be a U.S. citizen, lawful permanent resident of the U.S., protected individual as defined by 8 U.S.C. 1324b(a)(3), or eligible to obtain the required authorizations from the U.S. Department of State.
Swarm Aero is an equal opportunity employer. We value diverse backgrounds and experiences and make employment decisions without regard to race, religion, national origin, gender, sexual orientation, age, veteran status, or disability.
What We Offer
Meaningful equity in a high-growth defense technology company
Competitive base salary commensurate with experience
Medical, dental, vision, and 401k
PTO and paid sick leave
Monthly wellness stipend
Daily catered lunch (office)
Paid parental leave
Direct impact on a critical national security mission
A world-class team of engineers and operators solving genuinely hard problems