Principal Mechanical Engineer - Fixed-Wing UAS Launch SystemsFort Worth, Texas | On-site
Opportunity SummaryA venture-backed aerospace and defense startup developing advanced fixed-wing unmanned aircraft systems is seeking a Principal Mechanical Engineer to lead the architecture, design, and deployment of next-generation launch systems supporting runway-independent operations. Backed by active government programs and focused on rapidly deployable aircraft platforms, the company is building scalable systems designed for operational flexibility, field reliability, and manufacturable production. This is a principal-level individual contributor role with full ownership over launch system development across concept definition, mechanical architecture, actuation methods, field deployment strategy, and production readiness. The engineer will evaluate and develop launch approaches including pneumatic, hydraulic, rail, catapult, and bungee-assisted systems depending on mission requirements, aircraft configurations, and operational environments. The role requires deep hands-on engineering capability across mechanical design, structural systems, fluids, dynamic loading, and hardware integration while balancing portability, repeatability, operational simplicity, and manufacturing scalability. This individual will play a foundational role in defining how the company's aircraft are launched, deployed, transported, and operated in real-world environments.
Job Duties- Own the end-to-end design and development of launch systems for fixed-wing unmanned aircraft platforms
- Evaluate and define launch architectures including pneumatic, hydraulic, rail, catapult, and bungee-assisted systems
- Lead system trade studies balancing portability, deployment speed, reliability, manufacturability, aircraft compatibility, and operational efficiency
- Design and develop mechanical structures, launch rails, actuation systems, energy storage systems, deployment hardware, and supporting ground infrastructure
- Develop scalable launch solutions capable of supporting multiple aircraft configurations and future platform growth
- Optimize launcher systems for rapid deployment, repeatability, reliability, and reduced operator burden
- Support integration between launcher systems, aircraft mechanical interfaces, avionics, controls, and operational procedures
- Develop safety systems, operational procedures, interlocks, and field deployment workflows
- Perform mechanical analysis related to structural loading, dynamic response, energy transfer, vibration, fatigue, and system durability
- Coordinate prototype fabrication, assembly, integration, and field testing activities
- Support field operations, launcher testing, troubleshooting, and iterative hardware improvements
- Drive design maturity from prototype hardware through scalable production-ready systems
- Work closely with aerospace, manufacturing, avionics, flight test, and systems engineering teams to validate performance and operational readiness
- Support supplier engagement, component selection, and manufacturing process development
- Mentor junior engineers and provide technical leadership across launcher and mechanical system development efforts
Qualifications- 10+ years of mechanical engineering experience supporting aerospace, defense, launch systems, or complex electromechanical hardware
- Strong hands-on mechanical design experience involving structural systems, actuation mechanisms, dynamic systems, or high-force mechanical equipment
- Experience owning hardware systems from concept development through prototype and operational validation
- Familiarity with pneumatic, hydraulic, mechanical launch, or energy transfer systems
- Strong understanding of mechanical integration, tolerance stack-up, manufacturability, and field reliability
- Experience supporting hardware testing, troubleshooting, and rapid engineering iteration
- Proficiency with CAD and mechanical design tools
- Bachelor's degree in Mechanical Engineering, Aerospace Engineering, or related technical discipline
- Comfortable working in hands-on development and field test environments
- Strong first-principles engineering and technical decision-making capability
Preferred Experience- Direct experience with UAS launch systems or runway-independent aircraft operations
- Background supporting defense launcher systems or deployable aerospace hardware
- Experience with rail launch, catapult systems, pneumatic launchers, or hydraulic actuation systems
- Familiarity with mobile, trailer-mounted, or expeditionary support systems
- Experience supporting field operations, flight testing, or operational deployment environments
- Exposure to structural dynamics, vibration environments, or high-cycle mechanical systems
- Experience supporting rapid hardware development within startup or defense organizations
Why Join Us- Opportunity to architect and own a foundational aerospace system from the ground up
- Principal-level technical ownership with direct influence on aircraft operational capability
- Exposure to rapid aerospace development, field testing, and mission-driven hardware execution
- Collaborative engineering environment focused on real-world deployment and scalable manufacturing
- Early-stage company with significant technical ownership and long-term growth opportunity
Compensation Details$155,000 - $195,000
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