Mechanical Engineer

Harmattan AI

ABOUT US Harmattan AI is a next-generation defense prime building autonomous and scalable defense systems. Following the close of a $200M Series B, valuing the company at $1.4 billion, we are expanding our teams and capabilities to deliver mission-critical systems to allied forces. Our work is guided by clear values: building technologies with real-world impact, pursuing excellence in everything we do, setting ambitious goals, and taking on the hardest technical challenges. We operate in a demanding environment where rigor, ownership, and execution are expected. ABOUT THE ROLE As a Mechanical Engineer on Harmattan AI’s Airframe team, you will design UAV platforms and subsystems in an autonomous, fast-paced environment. You will take ownership of projects from concept through to production, ensuring optimal performance, reliability, and manufacturability. TECHNICAL SKILLS RESPONSIBILITIES * Design and prototype UAV platforms and complex subsystems from scratch, ensuring the right balance between durability, efficiency, and performance. * Take full ownership of system-level constraints, including thermal management, mass budget (weight), COGS (cost), and environmental sealing (IP ratings). * Work closely with R&D teams (Electrical, Software, and Industrialisation) to ensure seamless mechanical integration of sensors, payloads, and electronics. * Conduct rigorous testing, including stress and failure analysis. Identify risks proactively and develop the necessary tools (test benches, calculation sheets, or scripts) to validate designs for operation in extreme environments. * Manage your own delivery packages and technical specifications with precision, consistently meeting or exceeding requirements under tight deadlines. * Oversee the manufacturing process by collaborating directly with suppliers and external manufacturers, with a focus on plastic injection moulding and precision machining, to ensure quality and schedule targets are achieved. * Maintain the “source of truth” through Confluence and professional 2D/3D documentation. Document all designs, test results, and production workflows to support knowledge sharing and continuous improvement. CANDIDATE REQUIREMENTS * Master’s degree in Mechanical Engineering, Aerospace Engineering, or a related field. * Proven experience designing and prototyping mechanical systems, ideally within UAVs, robotics, or defence applications. * Proficiency in CAD software (e.g., SolidWorks); experience with structural and thermal analysis tools (FEA) is a strong advantage. * Strong understanding of manufacturing processes, including high-precision machining and plastic injection moulding. * Excellent written and verbal communication skills, with the ability to clearly document complex technical concepts and lead cross-functional discussions. * Full commitment to Harmattan AI’s mission, vision, and growth plans, with a willingness to go the extra mile in pursuit of operational excellence. We look forward to hearing how you can help shape the future of autonomous defense systems at Harmattan AI.

Harmattan AI

ABOUT US Harmattan AI is a next-generation defense prime building autonomous and scalable defense systems. Following the close of a $200M Series B, valuing the company at $1.4 billion, we are expanding our teams and capabilities to deliver mission-critical systems to allied forces. Our work is guided by clear values: building technologies with real-world impact, pursuing excellence in everything we do, setting ambitious goals, and taking on the hardest technical challenges. We operate in a demanding environment where rigor, ownership, and execution are expected. Harmattan is seeking a hands-on Aerothermal Engineer to join our Aerodynamics team. You will own the full thermal and aerothermal engineering cycle for our UAV platforms: from early design recommendations and simulation to wind tunnel experiments and flight test campaigns. Your work directly impacts the survivability, reliability, and performance of our systems in contested environments. You will be the technical authority on heat transfer, thermal management, and aerothermal interactions across all vehicle programs — working closely with aerodynamics, propulsion, mechanical, and GNC teams to ensure our platforms perform within thermal limits under real operational conditions. RESPONSIBILITIES * Aerothermal Design & Recommendations: Provide early-stage design guidance on thermal management architecture — including cooling inlet design, heat shield placement, exhaust routing, and surface coatings — to ensure airframes remain within thermal limits across the full flight envelope. * Thermal & Aerothermal Simulation: Set up, run, and validate lower fidelity thermal models, simulations and coupled thermal-fluid CFD tools (e.g., OpenFOAM). Model convective, conductive, and radiative heat transfer on internal components (batteries, motors, avionics) and external aerodynamic surfaces. * Design Optimization: Drive iterative aerothermal optimization cycles to minimize thermal drag penalty, reduce hotspot intensity, and maximize cooling efficiency. Leverage scripting and automated workflows to sweep design parameters and converge on optimal configurations. * Wind Tunnel Test Campaigns: Design, plan, and execute aerothermal wind tunnel experiments. Define instrumentation strategy (thermocouples, heat flux sensors, pressure taps), write test plans, operate test rigs, and lead post-test data analysis and correlation with simulation. * Flight Test Campaigns: Contribute to and lead in-flight thermal measurement campaigns. Define DAQ architecture for thermal sensors, develop test matrices, analyze flight data, and correlate with CFD predictions to validate models and sign off thermal margins. * Cross-functional Integration: Act as the thermal interface between the aerodynamics, propulsion, mechanical, and GNC teams — ensuring that thermal constraints are reflected in system-level trade-offs and that heat rejection requirements are accounted for in the airframe design. REQUIREMENTS * Education: B.S., M.S., or Ph.D. in Aerospace Engineering, Mechanical Engineering, or a related field with a strong focus on fluid mechanics and heat transfer. * AeroThermal Fundamentals: Solid theoretical grounding in convective, conductive, and radiative heat transfer; boundary layer theory; and viscous flow physics as applied to aircraft surfaces and internal cooling passages. * Thermal Simulation Proficiency: Hands-on experience with CFD simulations in at least one major solver (OpenFOAM, Star-CCM+, ANSYS Fluent/CFX, or equivalent). Ability to select appropriate thermal boundary conditions, turbulence models, and mesh strategies for accuracy. * Experimental Testing: Demonstrated experience planning and executing thermal measurement campaigns — either in wind tunnel or in-flight — including instrumentation selection, DAQ setup, data reduction, and uncertainty analysis. * Python Proficiency: Ability to script data processing pipelines, automate post-processing of thermal simulation outputs, and interface with experimental DAQ systems. * Technical Communication: Ability to translate complex aerothermal findings into clear design recommendations for multidisciplinary teams. NICE TO HAVE * General Aerodynamic Knowledge: Familiarity with the fundamentals of external aerodynamics — lift and drag generation, pressure distributions, boundary layer behaviour, and flow separation — as applied to fixed-wing or multirotor UAV platforms. * RC Knowledge: Hands-on experience building, flying, or tuning RC aircraft or drones — whether fixed-wing, quadcopter, or hybrid configurations. We look forward to hearing how you can help shape the future of autonomous defense systems at Harmattan AI.

Harmattan AI

ABOUT US Harmattan AI is a next-generation defense prime building autonomous and scalable defense systems. Following the close of a $200M Series B, valuing the company at $1.4 billion, we are expanding our teams and capabilities to deliver mission-critical systems to allied forces. Our work is guided by clear values: building technologies with real-world impact, pursuing excellence in everything we do, setting ambitious goals, and taking on the hardest technical challenges. We operate in a demanding environment where rigor, ownership, and execution are expected. ABOUT THE ROLE We are looking for a UAV Battery Engineer to join our Hardware (Elec Team). This role is critical to owning the energy storage systems that power our UAV platforms. Our drones demand high energy density, reliability, and uncompromising safety under dynamic loads — and we need a dedicated expert to architect, test, and deliver battery systems from cell selection through to production-ready packs. You will take end-to-end ownership of the UAV battery architecture, working hands-on with cells, BMS hardware, and thermal systems every day. This is a high-autonomy role where your decisions on cell chemistry, supplier selection, and safety protocols will directly shape the performance and reliability of our platforms. RESPONSIBILITIES Battery Architecture & Cell Selection: Evaluate and qualify battery cell suppliers based on energy density, cycle life, cost, and safety performance. Define pack configuration and cell architecture for UAV platforms. Battery Safety & Thermal Management: Lead the design of battery safety protocols, including thermal runaway mitigation and propagation resistance strategies. Conduct hazard analyses (DFMEA) and ensure compliance with standards such as UN38.3 and UL. BMS Design & Integration: Own the Battery Management System architecture and algorithms, including State of Charge (SoC) and State of Health (SoH) estimation, cell balancing, and protection logic for highly dynamic load environments. Testing & Validation: Perform hands-on testing of cells using cyclers and thermal chambers. Develop validation plans covering abuse scenarios such as overcharge, short circuit, and mechanical drop conditions. Analyse BMS log data and simulate thermal behaviour. Supplier Management: Manage relationships with cell suppliers, covering technical specifications, quality control, and roadmaps. Build a reliable and scalable supplier pipeline. Cross-Team Collaboration: Work closely with Mechanical Design on battery packaging constraints, Firmware on BMS parameters and algorithms, and external manufacturing partners. CANDIDATE REQUIREMENTS Educational Background: Bachelor's or Master's degree in Electrical Engineering, Mechanical Engineering, Materials Science, Chemical Engineering, or a closely related field. Technical Expertise: Proven track record of taking battery systems from concept to production in high-performance robotics, aerospace, or UAV applications. Hands-on experience with cell characterisation, BMS architecture, and thermal management. Familiarity with safety compliance standards (e.g., UN38.3, UL). Core Competencies: Cell selection and testing, supplier management and qualification, battery safety (thermal runaway mitigation), BMS architecture, pack packaging and integration, and regulatory compliance. Ideal Background: Experience at drone manufacturers (e.g., DJI, Skydio, Anduril), EV companies (e.g., Rivian, Tesla), or advanced robotics and electrification organizations. Attributes: Analytical, safety-conscious, data-driven, and highly structured. Strong communication skills, particularly for supplier negotiation and cross-functional collaboration. Commitment: 100% dedication to Harmattan AI's mission, vision, and ambitious growth plans, ready to go the extra mile to ensure operational excellence. We look forward to hearing how you can help shape the future of autonomous defense systems at Harmattan AI.