At Elroy Air we're building autonomous cargo aircraft systems that expand the reach of express logistics and deliver goods to the world’s most remote places. We are currently expanding our world class team of engineers, roboticists, & designers that are actively enabling autonomous aerial cargo delivery.
This is a full-time position at our headquarters in San Francisco, CA.
As Aerostructures Lead, you will drive our team’s efforts to model, design, evaluate, prototype, and manufacture our aircraft’s primary structures and a broad array of mission-critical components & systems.
Aerostructures Design & Development
- Driving the design of our cargo UAV’s system components around performance, manufacturability, cost, and scalability- e.g aircraft primary structures, landing gear, control surfaces, structural joints, access panels, etc.
- Sketching, whiteboarding, and helping to build team alignment on designs & determining ways to fabricate a wide range of aerostructures-focused project elements
- Building & reviewing 3D models in SolidWorks (or a complementary CAD package) of large and small composite components, structural assemblies, and associated metallic & plastic components.
- Assuring design for assembly/serviceability ensuring that mechanical and aerostructures efforts include thinking through and designing for: appropriate access panel locations, simple removal and installation of line replaceable units (e.g. turbines, lift motors, control surface servos, antennas, & drive motors), ease of fastener access.
- Design for Manufacturability: vetting selection of the right production processes for our applications, driving the development and inspection of a variety of shop drawings/CAD for vendors to ensure that parts are properly toleranced and meet performance goals.
- Aircraft Testing: driving the design of structural +/- mechanical testing plans and providing comments & feedback as needed, assisting with destructive and non-destructive airframe load testing and sharing test results with the team.
Strategy & Planning
- Shaping our strategy for how we plan to prototype and carry aircraft designs from low rate initial production (LRIP) to a high volume production environment.
- Defining the scope & strategies for Elroy Air’s efforts surrounding FEA / structural analysis, process & material selection, and weight optimization.
- Working with our Technical Program Manager to build design, development, testing, & production schedules that ensure we can hit both internally facing and externally facing deadlines. We take deadlines seriously.
Leadership & Management
- Defining a vision of how Elroy Air should design, develop, test, and produce our aircraft’s primary structures & components and building alignment on how we make that vision a reality.
- Sharing your subject matter expertise and mentoring teammates in our Mechanical Engineering group with the goal of fostering an environment of learning, professional growth and continuous improvement.
- Building and Maintaining Vendor Relationships: providing guidance to team in selecting development, prototyping & manufacturing partners that will best meet our program needs. Establishing regular calls & check-in visits with vendors to ensure that program needs and timeframe goals are met. Ensuring that vendors’ work is aligned with our aircraft performance, production, testing, regulatory, and business goals. Being onsite with vendors during critical phases of our aircraft builds to assure that everything goes smoothly and expectations are met.
Our Ideal Candidate Has
- An advanced degree in Aerospace or Mechanical Engineering (MS or Ph.D) with a focus on the design of composite aircraft structures
- Experience as a manager or a very strong individual contributor of high-performing Engineering teams with 3-to-10 (or more) personnel
- Deep aerostructures experience and the ability to drive composite aerostructures from clean sheet to production aircraft
- Firsthand working knowledge of materials, tooling & fixtures, resin systems, precision machining, and manufacturing processes for composite aircraft production
- 5-to-10 years of Aerospace and Mechanical Engineering experience directly pertaining to vehicle design or robotic systems
- Experience developing aircraft, vehicles, or robots utilizing high power drives or actuators
- Past experience designing for a wide variety of production processes including but not limited to machining, 3D printing, waterjet and laser cutting, welding, castings, injection molding, gluing & bonding, etc.
- The desire to: work within a fast-paced startup environment that expects excellence and embraces diversity. Build teams and processes from the ground up. Get their hands dirty. See their aircraft go to market.
- Experience and interest in designing for thermoplastic composite construction
- Past experience developing parts and structures for weight-constrained applications
- Past experience developing parts and structures involving large structural composite vehicles/robots/etc…
- Interest in defining how we will navigate the policies and standards for aircraft structures being set forth within an evolving regulatory landscape for commercial use of large UAVs (e.g. FAA, EASA, ASTM, etc . . .)
There are a lot of jobs out there that you could easily get, we know that. But - speaking without humility for a second - few will be nearly as exciting as this. Come join us!