Sam

Senior Mechanical Design Engineer

Intelligent Flight Company • Full time

May 2026 - Present • 6 mos

Leading the complete mechanical design domain for UAV and drone platforms, with full ownership of airframe architecture, structural design, and subsystem integration from concept to production. ● Defining mechanical design strategies for performance, durability and environmental requirements. ● Managing and mentoring a team of mechanical engineers while establishing efficient design workflows, review systems, and quality standards. ● Overseeing the development of composite structures (CFRP/GFRP), including plug and mold design, material selection, and manufacturing processes. ● Collaborating closely with aerodynamics, avionics, and propulsion teams to ensure seamless system integration. ● Driving DFM and DFA practices to optimize weight, cost, and manufacturability, while supervising prototyping, testing, and production transitions. ● Managing vendor coordination for CNC, additive manufacturing, and composite fabrication, ensuring quality and timely delivery. ● Contributing to R&D on advanced UAV configurations, modular payload systems, and high-performance lightweight structures.

Mechanical Design Engineer

Mach Alpha • Part time

Jul 2024 - Present • 2 yrs 4 mos

I collaborate with multidisciplinary aerospace design and analysis teams to develop UAV structures and exterior body components, making sure our designs can be efficiently converted for manufacturing. On a daily basis, I review and optimize CAD models and coordinate manufacturing methods such as 3D printing, CNC machining, and composite molding. I oversee material procurement for prototyping and manage external vendors for composite, CNC, and plastic parts. Key projects: > Firefighter UAV: designing and fabricating a coaxial hexacopter with a 10-liter tank, using 3D printing, CNC machining, and composite manufacturing. > Electric VTOL UAV: supervising the fabrication and internal structural design of an electric VTOL carrying a 20 kg payload over a 63-mile range.

Mechanical Design Engineer

Aero Vision Technologies • Full time

Jun 2023 - Jun 2026 • 3 yrs

As lead designer for UAV mechanical systems, I managed the complete development process, from CAD modeling through prototyping to final production. I optimized each design for cost-effective, scalable manufacturing, coordinated 3D printing, CNC machining and composite molding, oversaw material procurement for prototypes, and managed vendors for composite, plastic and CNC parts. I also mentored interns and support staff in CAD, prototyping and manufacturing. Key projects: > Kestrel quadcopter: designed and fabricated in-house, carrying a 2.5 kg payload, with modular landing gear and foldable arms. > Skywing VTOL upgrade: brought the UAV to an IP44 rating and rebuilt the payload bay for dual sensor integration. > A UAV to assist first responders.