Senior Mechanical Engineer - Structural Analysis

At Heart Aerospace, we’re shaping the future of sustainable aviation with the ES-30, a regional hybrid-electric aircraft designed to carry 30 passengers with a 200 km all-electric, zero-emission range and an extended 400 km hybrid range. Heart is targeting type certification by the end of the decade. Your Mission As a Mechanical Design Engineer, Structures & Airframe, you will design, analyze, and develop aircraft structural components. You will collaborate cross functionally to the design of the fuselage, wing, and empennage, working with both composite and metallic materials, while gaining hands-on exposure to certified aerospace hardware development in a fast-paced, collaborative environment. This is an exciting opportunity for a mechanical or aerospace engineer to contribute to the design and development of next-generation aircraft structures while building strong engineering fundamentals and growing into increased technical responsibility over time. Key Responsibilities include but are not limited to: * This role is a Responsible Engineer (RE) who focuses on the design and development of aircraft structural components. * Create and release 3D CAD models, 2D drawings, and documentation using NX/Teamcenter or equivalent tools. * Optimize structural performance for cost and mass. * Perform structural analyses, hand calculations, and FEA activities with mentorship. * Define structural requirements, specifications, and test plans. * Own structural testing activities, data review, and documentation. * Collaborate with manufacturing, quality, and test teams to resolve design and build issues. * Participate in design reviews, continuous improvement and best practices. * Learn and apply aerospace standards, GD&T, and manufacturing fundamentals. (This position can be hired as a Mechanical Design Engineer II or Senior Mechanical Design Engineer)  Skills & Requirements: You'll Bring These Qualifications for Mechanical Design Engineer II, Structures & Airframe: * 2+ years of professional experience in structural design, aerospace engineering, or a related field. * Experience with CAD tools such as Siemens NX, CATIA, Creo, or SolidWorks * Understanding of engineering fundamentals, structural mechanics, and first principles * Exposure to composite and/or metallic structures through coursework, projects, or early industry experience * Familiarity with GD&T and basic manufacturing concepts * Strong written and verbal communication skills in English * Ability to work collaboratively in a team environment and take technical direction * Passion for aircraft design and interest in sustainable aviation You'll Bring These Qualifications for a Senior Mechanical Design Engineer, Structures & Airframe: * 5+ years experience in composite structural design * Experience with CAD tools such as Siemens NX, CATIA, Creo, or SolidWorks * Understanding of engineering fundamentals, structural mechanics, and first principles * Familiarity with GD&T and basic manufacturing concepts * Strong written and verbal communication skills in English * Ability to work collaboratively in a team environment and take technical direction * Passion for aircraft design and interest in sustainable aviation Education: * Bachelor’s degree in Aerospace Engineering, Mechanical Engineering, or a related field. These Qualifications Would Be Nice to Have: * Worked in a startup environment. * Hands-on exposure to composite or aluminum part fabrication. * Familiarity with NX, CATIA, or other advanced CAD platforms. * Academic or early exposure to FAA/EASA certification concepts. * Introductory experience with FEA tools and structural analysis methods. * Experience leading or working with structural testing, instrumentation, or data analysis. * Master’s degree (or progress toward one) in Aerospace or Mechanical Engineering. Base Pay Range: * Mechanical Design Engineer II - $124,000 - $155,000. * Senior Mechanical Design Engineer - $140,000 - $176,000.

ABOUT US Harmattan AI is a next-generation defense prime building autonomous and scalable defense systems. Following the close of a $200M Series B, valuing the company at $1.4 billion, we are expanding our teams and capabilities to deliver mission-critical systems to allied forces. Our work is guided by clear values: building technologies with real-world impact, pursuing excellence in everything we do, setting ambitious goals, and taking on the hardest technical challenges. We operate in a demanding environment where rigor, ownership, and execution are expected. We are seeking a high-drive, hands-on Senior Mechanical Engineer to join our dedicated Quadcopter Airframe team in Lausanne. In this role, you will own the end-to-end mechanical architecture of our flagship multirotor platforms—from initial CAD concept and structural design to payload packaging, physical prototyping, and production release. From day one, you will take full ownership of real hardware: designing complex assemblies in SolidWorks, solving heat and vibration challenges, running lab validation, and driving parts through production alongside our cross-functional engineering teams. WHAT YOU WILL DO * Quadcopter & Subsystem Architecture: Lead the mechanical design and modeling of lightweight quadcopter structures, fuselages, chassis, motor mounts, and quick-release mechanisms in SolidWorks from concept to production. * Electromechanical Packaging: Lead spatial layouts and enclosure design to integrate electrical components (PCBs, wire harnesses, power distribution, motors, and sensors) tightly into custom airframe volumes. * Rapid Prototyping & Physical Testing: Build functional prototypes and execute hands-on lab validation—including vibrational testing, modal analysis, thermal chamber runs, drop testing, and assisting with flight tests. * Simulation & Thermal Analysis: Perform structural (FEA), modal, and thermal simulations alongside tolerance stack-up analyses to ensure designs withstand extreme defense operational environments. * DFM & Production Documentation: Partner with Industrialisation, Procurement, and suppliers to optimise parts for plastic injection molding, CNC machining, sheet metal, and additive manufacturing. * Assembly Enablement: Support Industrialisation engineers in defining assembly sequences, designing build jigs and fixtures, and training production operators to ensure high build quality and fast throughput. WHAT WE ARE LOOKING FOR * Background: M.Sc. or B.Sc. (FH / HES / University of Applied Sciences) in Mechanical Engineering or a related technical field. * Experience: * 4+ years of hardcore, hands-on UAV design and development experience (demonstrated track record with physical drone airframes, multirotors, or flight hardware), OR * 6+ years of overall mechanical engineering experience in complex Robotics, Autonomous Systems, or high-density Electromechanical hardware. * End-to-End Ownership: Proven track record taking complex electromechanical assemblies from CAD concepts through functional prototypes to finished, physical production hardware. * DFM Grounding: Practical design experience for plastic injection molding, CNC machining, sheet metal, and 3D printing, with direct supplier collaboration experience. * Applied Physics & Problem Solving: Demonstrated skill in managing real-world physical constraints—including structural rigidity, heat dissipation, and vibration isolation. * High Ownership & Drive: Proactive, responsive, and collaborative mindset—someone who takes full responsibility for their work and actively unblocks themselves under tight deadlines. WHAT WE OFFER * Complete System Ownership: Own the complete mechanical architecture of flagship quadcopter platforms rather than being siloed on a single bracket or cover. * Unmatched Execution Speed: Move from CAD design to physical shop-floor testing in days, backed by strong resources and quick decision-making. * Direct Mission Impact: Design and build hardware that actively deploys with allied forces to solve critical defense challenges. * Cross-Functional Mastery: Work side-by-side with Electrical, Aerodynamics, Gimbal, and Production teams with complete visibility over how hardware moves from CAD to active flight. We look forward to hearing how you can help shape the future of autonomous defense systems at Harmattan AI.