Mid Level Mechanical Engineer

i3 is seeking a Mid-Level Mechanical Engineer to support a rapidly evolving, low-cost, novel system. You will be responsible for the rapid design, fabrication, and iteration of sUAS platforms. The position involves collaborating with a small, diverse team of engineering professionals to ensure project goals and timelines are achieved. This position is in Huntsville, Alabama, and the candidate can expect up to 10% travel.

This position is contingent upon contract award, with an estimated timeframe of December 2025.

• Generate design drawings and system schematics as well as conduct analysis to support and substantiate design approaches.
• Design and model drone airframes, sensor mounts, and electro-mechanical components using CAD software.
• Assemble and integrate all components—including motors, flight controllers, sensors, and payloads—into functional drone prototypes.
• Support the rapid iteration cycle: flight test, identify points of failure or areas for improvement, and implement design changes for the next build.
• Collaborate with the broader engineering team to ensure mechanical designs meet the requirements of our autonomy and mission systems.
• Generation of test plans, technical reports, and presentations documenting the work performed.
• Operate 3D printing & process equipment for printed component fabrication.
• Monitor operating parameters on production builds such as build times, early identification of defects, and material consumption rate.
• Identify and troubleshoot mechanical, optical laser, electrical, and build issues.
• Utilize measurement tools (micrometer, caliper, surface plate etc.) to ensure high quality inputs and outputs, including post-print inspection and post-processing inspection.
• Work alongside an interdisciplinary team of mechanical, electrical, and software engineers to analyze in-situ data as well as post-print material characteristics and rapidly iterate on improving the printing technology.
• Perform failure analysis and investigation into prints, printheads, and printers to identify and implement solutions.
• Support engineering efforts in preparation for Critical Design Reviews (CDRs).
• Assist in the coordination with key vendors and/or suppliers.
• Other duties as assigned.

Education/Experience

• Bachelor’s Degree in an applicable engineering area (mechanical, aerospace, manufacturing, and engineering technology, etc.) Additional experience may substitute for degree.
• 2-7 years of experience in mechanical design, robotics, or a related field with a portfolio of hands-on projects.
• Fundamental understanding of drone components (flight controllers, ESCs, motors, communication links) and basic aerodynamic principles.
• Knowledge and/or experience in the design and analysis of mechanical systems.
• Knowledge and/or experience in the use of CAD software including Creo, Solid Works and/or Inventor.
• Ability to obtain and maintain a DoD security clearance.
• Ability to travel to suppliers as required.
• U. S. Citizenship is required.

Knowledge/Skills

• Excellent communication, teamwork, and client service skills; ability to clearly communicate in discussions and written documents, and to deliver feedback clearly and tactfully.
• Be extremely organized and exceptionally detail oriented.
• Work well both independently and in a team environment.
• Be energized by a fast-paced work environment.
• Must be able to communicate with others effectively.
• Manage time wisely and prioritize tasks.
• Work well under pressure.

Physical Demands

• The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job.
• While performing the duties of this job, the employee is regularly required to talk or hear. The employee frequently is required to stand; walk; handle or feel; and reach with hands and arms.
• The employee is occasionally required to sit; climb or balance; and stoop, kneel, crouch or crawl. The employee must be able to lift and/or move up to 10 pounds and occasionally lift and/or move up to 25 pounds.

i3 is a technically diverse, 100% team member owned business, headquartered in Huntsville, Alabama specializing in missile and aviation systems engineering and logistic services, electronic warfare and electromagnetic effects analysis, UAS system integration and flight operations, full lifecycle C5ISR engineering services, cybersecurity and IT/IA innovative solutions and virtual training, simulation & serious game development and implementation. We have established a broad offering of products and capabilities collectively providing decades of experience supporting the full complement of DoD military services, Missile Defense Agency, National Aeronautics and Space Administration, and a variety of other Government organizations and private industry customers.  

Perks of being a team member owner include:

• Long-term financial security
• Higher job satisfaction
• Greater job security
• Personal and professional growth
• Great company culture

Other outstanding benefits:

• Excellent insurance coverage
• 401(k) match
• Generous PTO
• Health and wellness incentives
• Tuition and certification reimbursement
• Countless opportunities to give back to the community through i3 Cares

We work hard. We compete hard. We play hard. Apply now to join us!