Senior Mechanical Engineer, DFM Focus

Senior Mechanical Engineer, W/ Focus On Design For Manufacturability

DZYNE Technologies is leading the future of autonomous defense. Based in Irvine, California, we develop and manufacture advanced airborne and ground-based defense solutions deployed in over 50 countries. Backed by U.S. Government Programs of Record, our technologies are field-proven, scalable, and production-ready. We're growing fast, and looking for innovators ready to make an impact. At DZYNE, you'll join a culture built on collaboration, integrity, and purpose. We celebrate wins, value diverse perspectives, and support every team member's success. Ready to do work that matters? Join us.

Position Title: Senior Mechanical Engineer, W/ Focus On Design For Manufacturability

Location: Irvine, CA

Work Arrangement: 100% On-site

Position Summary: We are seeking a Senior Mechanical Engineer with a strong background in high-volume product development and production-oriented mechanical design. This role focuses on creating robust, manufacturable components and assemblies for unmanned aircraft systems, with emphasis on Design for Manufacturability (DFM) and Design for Assembly (DFA) at production rates of 1,000+ units per month. The ideal candidate has hands-on experience selecting appropriate manufacturing processes, driving cost-efficient designs, and collaborating closely with electrical, manufacturing, and integration teams. Our aircraft require dense packaging of mechanical, electrical, propulsion, and avionics subsystems; success in this role depends on the ability to balance structural needs with aerodynamic, electrical, thermal, and routing constraints within limited volumes. This position provides the opportunity to influence system-level design decisions, guide manufacturing strategy, and mentor junior engineers while contributing directly to hardware transitioning from prototype to scalable production.

Required Duties And Responsibilities:

• Lead mechanical design of airframe structures, housings, and mechanically complex assemblies intended for high-volume production environments.
• Drive DFM and DFA principles from concept through release, ensuring designs are optimized for repeatability, cost, and quality at volumes of 1,000+/month.
• Select appropriate manufacturing processes (e.g., injection molding, stamping, die casting, compression molding, machined components) based on performance, cost, and production scale.
• Collaborate closely with electrical engineering to integrate batteries, motors, avionics, sensors, and wiring within constrained aircraft volumes.
• Collaborate closely with Aero engineering to ensure the finished product meets the aerodynamical criteria such as surface roughness, steps and gaps.
• Perform tolerance analysis, evaluate material choices, and assess manufacturability trade-offs.
• Work directly with manufacturing engineers, suppliers, and production teams to validate tooling, address build issues, and improve assembly efficiency.
• Generate detailed CAD models, assemblies, and production documentation under configuration control.
• Support prototype builds and conduct hands-on troubleshooting during integration and testing.
• Provide technical mentorship and guide junior engineers in best practices for high-volume mechanical design.

Required Skills/Qualifications:

• 7+ years of experience in mechanical design for aerospace, consumer electronics, automotive, robotics, or similar electromechanical products.
• Proven track record of designing components and assemblies for high-volume production (1,000+/month).
• Strong understanding of DFM, DFA, tooling considerations, and manufacturing cost drivers.
• Fluency with 3D CAD tools (SolidWorks preferred), including advanced part and assembly design.
• Experience collaborating with electrical teams, including familiarity with harness routing, PCB packaging, and integration of electrical components.
• Familiarity with manufacturing processes conducive to volume of 1,000+/month, such as injection-molded plastic, sheet metal stamping, aluminum die-cast, aluminum extrusion, or compression-molded composites.
• Strong understanding of tolerance stack-ups, material selection, and mechanical fundamentals.
• Able to communicate effectively across disciplines and with external suppliers.

Preferred Skills/Qualifications:

• Experience with injection-molded, stamped, die-cast, extruded, or compression-molded components.
• Experience bringing products through tooling, pilot builds, and scaling to production.
• Familiarity with production automation, fixture design, or assembly line considerations.
• Background working on compact electromechanical systems requiring tight packaging constraints.
• Experience with aircraft, unmanned systems, robotics, or similar products
• Exposure to composites manufacturing and lightweight structural design.
• Experience qualifying suppliers or working with manufacturing partners.

Education: Bachelor's degree in Mechanical Engineering, Aerospace Engineering, or a related STEM field from an accredited institution

Clearance Level Required: None required.

Export Control / ITAR Requirement: This position requires access to information and technology subject to U.S. export control laws and regulations, including the International Traffic in Arms Regulations (ITAR). As a result, employment is contingent upon meeting applicable export control eligibility requirements and compliance obligations.

Travel Required: Less Than 10%

Working Conditions: The diversity of work conditions may range from an environment where there is little or no physical discomfort, such as a general office environment, to warehouse and other facilities.

Physical Demands: The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job:

• Must have the ability to stoop, stand, climb, occasionally lift a minimum of 25 lbs.
• Involves movement between departments, floors, and worksites to facilitate work.

Work Authorization Requirement: Candidates must be legally authorized to work in the United States on a full-time basis without the need for current or future employment visa sponsorship.

Salary: $130,000 – $190,000 Annually Salary depends on relevant work experience, education, training, essential skills, and/or other factors such as specialized or high-demand professions. In addition to the annual salary, the position will be eligible for an annual bonus. The pay range for this job level is a general guideline only and not a guarantee of salary or annual bonus.

Benefits: Our benefits are DZYNE'ed for your overall health and financial wellness. DZYNE offers a comprehensive healthcare benefits package. Base dental, vision, life, accident, disability, and other core benefits are fully covered by DZYNE. DZYNE provides paid time off and paid holidays. Additionally, DZYNE offers a 401 (k) plan with an employer match and immediate vesting.

DZYNE Technologies is an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race, color, sex, national origin, disability, or protected veteran status. In addition to federal law requirements, DZYNE Technologies complies with applicable state and local laws governing nondiscrimination in employment in every location in which our company has facilities. This policy applies to all terms and conditions of employment.