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Swarm Aero is building autonomous UAV swarms designed to operate in contested environments where reliability is mission-critical. The company is developing the largest swarming UAV platform and Command & Control software to coordinate thousands of heterogeneous autonomous assets. The team brings deep aerospace expertise from Scaled Composites, Airbus, Archer Aviation, Blue Origin, and Boom Supersonic, and has designed and built 30+ novel aircraft.
In this role, you will design and develop aircraft avionics enclosures and secondary structure for harsh-environment operation. You'll work across mechanical, avionics, and integration teams to ensure enclosures meet aerospace standards and perform reliably in field conditions.
Key responsibilities include:
- Design and develop avionics enclosures and secondary structure, including analysis and testing
- Integrate avionics devices into the airframe by specifying or creating mounts and brackets
- Define and implement mechanical design standards and requirements for avionics enclosures
- Develop and maintain mechanical models, drawings, and Interface Control Documents (ICDs) using CAD tools
- Collaborate with suppliers on Design for Manufacturability (DFM) to optimize cost, manufacturability, and lead-time
- Support flight test anomaly investigation and root cause analysis on avionics-related mechanical faults
- Contribute to airworthiness documentation and flight authorization packages
Requirements:
- 3+ years of enclosure design experience on aerospace, defense, UAS platforms, or similar harsh-environment industries
- Strong familiarity with aerospace mechanical design standards and ability to communicate design intent using ASME 14.5 GD&T
- Proficiency with CAD tools (NX, Solidworks, Catia, Creo Parametric, or equivalent)
- Experience designing with materials including aluminum, copper, polymers, and composites
- Experience with metal shaping processes (CNC machining, laser cutting, waterjet, bending, stamping)
- Experience with coatings and sealants (paint, plating, chemical conversion)
- Experience taking components and systems from design through hardware integration and test
- US person status required (ITAR compliance); active security clearance a plus
Nice to have:
- UAS or unmanned aircraft program experience
- Electrical harness design, routing, and integration
- DO160, MIL-STD-810, or related environmental test standards
- MIL-STD-461 testing, EMI/EMC analysis and mitigation on flight vehicles
- Defense programs or military airworthiness processes
- Sheet-metal or composites design (professional or hobby)
- PCB design or embedded electronics background
- Scripting experience
