Sam

Senior Mechanical Design Engineer

Airbus • Full-time

May 2026 - Present • 3 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. ● Responsible for defining mechanical design strategies aligned with defense requirements, including performance, durability, and environmental constraints. ● 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 multidisciplinary teams such as aerodynamics, avionics, and propulsion 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. ● Actively contributing to R&D initiatives focused on advanced UAV configurations, modular payload systems, and high-performance lightweight structures.

Mechanical Design Team Lead

Mach Alpha • Part-time

Jun 2024 - Present • 2 yrs 2 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 various manufacturing methods, such as 3D printing, CNC machining, and composite molding. I oversee material procurement for prototyping and manage communication with external vendors to fabricate composite, CNC, and plastic parts. Throughout every stage of our projects, I actively contribute to the design and development of critical UAV components, ensuring manufacturability and solid performance. Some of the key projects I’m working on include: >Firefighter UAV: I’m designing and fabricating a coaxial hexacopter with a 10-liter tank, utilizing 3D printing, CNC machining, and composite manufacturing techniques. >Loitering Munition (Fixed-Wing): I’ve designed the internal structure for a fixed-wing loitering munition that features a 1.5-meter wingspan and a 2 kg payload capacity. >Electric VTOL UAV: Currently, I’m supervising the fabrication and internal structural design of an electric VTOL capable of carrying a 20 kg payload over a 63-mile range. >Advanced Loitering Munition (In Development): I’m currently working on the design of a new loitering munition, drawing inspiration from platforms like Shahed, Harop, and Banshee.

Mechanical Design Team Lead

Aerodium • Full-time

Jun 2023 - May 2026 • 2 yrs 11 mos

I’m a Mechanical Design Engineer with a strong focus on aerospace systems and UAV development, specializing in the design and optimization of composite structures including CFRP and GFRP components. My expertise spans the full product lifecycle > from conceptual CAD modeling to functional prototyping using 3d printing and production-ready assemblies. Skilled in tools like SolidWorks, Siemens NX, and Ansys, I bring ideas to life using surface modeling, plug and mold design, and advanced composite manufacturing methods. I have designed a wide range of UAVs, including high-speed quads, VTOL systems, firefighting drones, and payload-carrying hexacopters, balancing performance, durability, and manufacturability in every solution. My work combines design for manufacturing (DFM/DFA) principles with GD&T, enabling smooth transitions from digital models to physical products. Whether it’s aerial robotics, UAV's or loitering munitions, I bring precision, creativity, and reliability to every project. I’m always eager to take on new challenges in mechanical design, UAV development, and advanced prototyping. Let’s connect if you’re working on something that flies or needs to.