Senior Mechanical Engineer

Job Details Job Location: Apium - San Diego, CA 92121 Salary Range: $120,000.00 - $166,000.00 Position Summary Apium Swarm Robotics (ASR) is revolutionizing swarm autonomy software for air, surface, undersea, and ground vehicles operating across dual-use commercial and defense environments. Our systems are deployed on real platforms, tested in the field, and delivered to customers operating in complex, uncertain, and safety-critical conditions. We do not build research prototypes or slideware. Our software is integrated into real vehicles, tested in the field, and delivered to customers who depend on operational reliability, speed of execution, and mission relevance. We prioritize performance over hype. ASR systems represent the next phase in autonomy: collaborative swarming. These are not like pre-programmed drones for light shows. We are creating real-time cooperative management that lets one operator control dozens to hundreds of vehicles in real-time with the ease of controlling a single vehicle. As such, this role requires comfort with responsibility, ambiguity, and operational accountability. ASR seeks a mechanical engineer to join our hardware development team. This role targets a designer and builder capable of owning the full lifecycle of physical hardware—from concept through manufacture—across a range of enclosure, packaging, and drone integration products. Primary responsibilities include the design and manufacture of Dongle Cases and Bridge Boxes, the ruggedized electronic enclosures central to ASR’s ground station and communications infrastructure. Unlike many hardware roles, ASR’s compact swarm platform allows mechanical work to be prototyped and iterated quickly, with in-house 3D printing and a bias toward rapid, field-testable designs. Travel may be required for field testing and demonstrations which will allow you to witness firsthand how your hardware performs as dozens of drones take flight. Position will also encompass the design, testing, and manufacture of drone attachments and physical modifications—from simple mounting brackets to complex multi-axis actuators—as well as the development of mechanisms supporting ASR’s “swarm in a box” concept: self-contained, rapidly deployable swarm systems with integrated logistics, charging, and launch capability. The role includes responsibility for ASR’s swarm packaging program: specifying, sourcing, and customizing Pelican case configurations and precision-cut foam inserts to ensure vehicles and ground equipment survive transport and deployment in demanding field environments. Essential Duties and Responsibilities Design and oversee manufacture of Dongle Cases, Bridge Boxes, and other ruggedized electronic enclosures; Specify, source, and customize swarm packaging solutions including Pelican cases and precision foam inserts; Design, test, and manufacture drone attachments and physical modifications, from simple brackets to actuated mechanisms; Collaborate with the engineering team on “swarm in a box” mechanism design, prototyping, and field validation. Required Qualifications Proficiency in 3D CAD modeling software (SolidWorks, Fusion360, or equivalent); Hands‑on experience with FDM and/or resin 3D printing, including material selection and print optimization; Practical knowledge of 3D printing materials including PLA, PETG, ABS, TPU, Nylon, and composite variants; Experience building, flying, or modifying UAVs and familiarity with drone hardware ecosystems; Understanding of robotics mechanisms including servo and stepper motor integration, linkages, and motion systems; Industrial design competency including IP/ingress protection ratings, vibration tolerance, thermal management, and impact resistance; Basic understanding of LiPo and lithium‑ion battery systems, charging architectures, and associated safety considerations; Experience designing enclosures and hardware for field deployment, including considerations for sealing, ingress protection, and structural durability; Ability to work effectively within a cross‑functional team alongside software, electrical, and systems engineers; Comfort working independently with limited oversight; Ability to remain calm and effective under operational pressure. Additional Desired Qualifications BS in Mechanical Engineering or related field; Experience with injection molding, vacuum forming, or other production‑scale manufacturing processes; Experience with CNC machining, laser cutting, or other subtractive and precision fabrication methods; Familiarity with MIL‑SPEC, MIL‑STD‑810, or equivalent environmental qualification standards; Experience with EMI/RFI shielding considerations in enclosure design; Experience specifying and working with custom foam fabrication, including CNC‑cut foam inserts for equipment cases; Experience with FPV racing, custom drone builds, or UAS competition platforms; Basic electronics knowledge sufficient to collaborate on PCB mounting, connector selection, and wire routing within enclosures; Experience with GD&T (Geometric Dimensioning and Tolerancing) and tolerance stack‑up analysis; Familiarity with pneumatic, hydraulic, or cable‑driven actuation systems; Experience with finite element analysis (FEA) or computational fluid dynamics (CFD) tools; Previous experience supporting hardware programs in defense, aerospace, or other safety‑critical environments; Strong mechanical, electrical, or systems troubleshooting skills; U.S. security clearance or ability to obtain one. Physical Requirements and Working Conditions Must be able to walk, stand, and navigate large indoor and outdoor facilities for extended periods. Ability to lift, carry, and move materials and equipment weighing up to 25lbs regularly. 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 need 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 may be 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. Requirement to travel up to 25% of the time, based on customer integration needs and operational requirements. 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 in E‑Verify to ensure eligibility for employment and compliance with Right to Work rules. Compensation Base pay, plus a generous annual equity package and potential bonuses. #J-18808-Ljbffr