Job DetailsJob Location: BlueOps (FL) - West Palm Beach, FL 33411Position 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.
Qualifications
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.
Qualifications
Job ID: 518076762
Originally Posted on: 4/20/2026
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