Senior Product Design Engineer - Structures Specialist

About the role

Skydio’s mechanical systems are the backbone of reliable autonomous flight. Our aircraft demand world‑class engineering, rigorous attention to detail, and disciplined design tradeoffs in pursuit of simplicity and performance. In this role, you will architect, analyze, and refine structural solutions that enable high‑performance autonomous flight and ensure fleet durability  flying robotics, mass and vibration are critical—your expertise in structural analysis and materials will directly shape flight time, dynamics, and overall system reliability.

• Play a key role in the design of Skydio aircraft by concepting, designing, and optimizing components with critical structural and mechanical considerations.
• Conduct a broad range of structural analyses, including linear and nonlinear static stress, modal, vibration, and shock to ensure durability and flight readiness under neutral and operational loads.
• Develop, mesh, and analyze detailed Finite Element Models (FEMs) of vehicle airframes, subsystems, and payload mounts using industry‑standard tools (e.g., NASTRAN, FEMAP, ANSYS, Abaqus, Hyper Mesh).
• Interpret and document analysis results, identify potential failure modes, and recommend design improvements to optimize mass, stiffness, and manufacturability.
• Design and execute lab experiments to test and validate FEA models, driving higher confidence in structural performance and design decisions.
• Design, instrument, and execute physical tests to validate and correlate FEA models, driving higher confidence in structural performance and design decisions.
• Design and analyze structures for drones and ground support hardware—such as fuselage frames, gimbals, mounting brackets, and enclosures—using a variety of materials such as plastics, metals, and composites.
• Select and evaluate materials, manufacturing processes, and joining methods (e.g., fasteners, snaps, adhesives) balancing weight, strength, manufacturability, cost, and environmental factors.
• Collaborate closely with design, test, manufacturing, and supply chain teams to ensure structural feasibility, reliability, and quality of production hardware.
• Partner with the Autonomy team to ensure the aircraft design continues to enable industry‑leading computer vision and obstacle avoidance.

• 5+ years of prior product development experience with a proven track record of execution, enthusiasm, and collaboration.
• Detailed structural analysis (FEA) of complex mechanical systems (preferably aerospace structures) using tools like NASTRAN, FEMAP, ANSYS, Abaqus, or similar.
• Structural hardware design, material selection (metals, composites), fabrication support, and/or structural testing (static/dynamic) for high‑performance applications.
• Familiarity with stuff that flies highly desirable, but not required.
• Proficiency with at least one major FEA software package (NASTRAN preferred).
• Familiarity with CAD software (e.g., Solid Works, Creo, NX, CATIA) for model review and basic geometry manipulation.
• Understanding of materials, manufacturing processes, and structural testing methodologies.
• Hands‑on experience in planning, executing, and correlating structural tests (static, vibration, acoustic, shock).
• Bachelor’s degree or higher in aerospace or mechanical engineering or equivalent with demonstrated academic excellence.
• Ability to apply analytical problem‑solving skills and engineering fundamentals to create high‑quality designs for a sophisticated vehicle system.
• A strategic mind across the full design, source, build, validate, and ship process. Proven ability to make considered decisions at various stages.

At Skydio, our compensation packages for regular, full‑time employees include competitive base salaries, equity in the form of stock options, and comprehensive benefits packages. Compensation will vary based on factors, including skill level, proficiencies, transferable knowledge, and experience. Relocation assistance may also be provided for eligible roles. The annual base salary range for this position is $145,000 – $250,000*. Fundamentally, we believe that equity is the key to long‑term financial…