New Products Mechanical Design Engineer

About You and The Role

The New Products team invents Zipline’s next generation of systems. We’re looking for exceptional mechanical designers to develop the lightweight structures and precision mechanisms that enable entirely new aircraft capabilities.

You thrive in ambiguity and enjoy creating hardware that has never existed before. Whether your expertise is in composite structures, mechanisms, or both, you combine strong engineering fundamentals with a hands-on approach to rapidly turn ideas into reliable hardware. You are comfortable moving between concept generation, analysis, CAD, prototyping, testing, and manufacturing, always balancing performance, weight, reliability, manufacturability, cost, and schedule.

You have a track record of solving difficult engineering problems through first-principles thinking, rapid experimentation, and sound technical judgment.

What You'll Do

• Own end-to-end mechanical subsystem delivery for assigned scope (examples: wing/centerbody structure, landing/release mechanisms, payload bay interfaces, or actuation systems) from concept through production release and field deployment.
• Translate mission requirements (mass budget, MTBF targets, operational duty cycles, environmental exposure, and turnaround time) into concrete designs, CAD, tolerance stacks, and verification plans.
• Produce and release drawings, GD&T, BOMs, and supplier specifications; coordinate part qualification, change control, and supplier handoffs to manufacturing partners.
• Drive test campaigns: design test fixtures, lead lab and flight-test instrumentation, execute structural and mechanism validation, collect data, and close failure modes against defined acceptance criteria.
• Use first-principles analysis and FEA to set margins, predict loads and fatigue life, and iterate designs to meet quantified targets (mass, stiffness, life, and safety factors).
• Rapidly prototype and iterate in-shop: build assemblies, lead bench and environmental tests, and convert validated prototypes into producible designs with documented producibility improvements.
• Collaborate daily with aerodynamics, structures, controls/autonomy, flight test, manufacturing, and operations teams; own cross-functional tradeoffs and be the mechanical authority in design reviews.
• Deliver measurable outcomes: reduce subsystem mass within specified range, demonstrate target MTBF or cycle life in test, close validation test plans to signoff, and achieve on-time drawing release for production runs.

What You'll Bring

• Required: 5+ years designing mechanical systems for aerospace, robotics, automotive, or similarly demanding hardware programs, with direct experience moving hardware from prototype to production.
• Required: Demonstrated hands-on experience with composite or metallic structural design and/or precision mechanisms (laminates/bonded joints, load path design, bearings, linkages, latches, or actuation systems). Provide concrete examples of subsystems you owned.
• Required: Proficiency in CAD (NX, SolidWorks, or equivalent), GD&T, FEA workflow for structural substantiation, and familiarity with test methods for fatigue, environmental, and life testing.
• Required: Experience producing production drawings, BOMs, supplier specs, and participating in supplier qualification and change-control processes.
• Required logistics: This role is onsite at our engineering lab/manufacturing campus with frequent hands-on build and test work; expect regular participation in flight-test campaigns and periodic travel (program-dependent) to launch/field sites.
• Required traits: rigorous first-principles problem solving, data-driven validation mindset, and willingness to work at the bench alongside technicians during iterative test cycles.
• Nice to have: Python or MATLAB for data analysis, experience with bonded composite manufacturing or automated layup, prior responsibility for structural substantiation or certification artifacts, and prior work on safety-critical aircraft subsystems.
• Nice to have: Patents, commercialized products, or exceptional personal engineering projects demonstrating creativity and craftsmanship.
• Constraints: This posting preserves the role scope and seniority; Zipline may sponsor work authorization where applicable.

What Else You Need To Know

The starting cash range for this role is $135,000 - $220,000. Please note that this is a target, starting cash range for a candidate who meets the minimum qualifications for this role. The final cash pay for this role will depend on a variety of factors, including a specific candidate's experience, qualifications, skills, working location, and projected impact. The total compensation package for this role may also include: equity compensation; discretionary annual or performance bonuses; sales incentives; benefits such as medical, dental and vision insurance; paid time off; and more.