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Zipline

Builds and runs autonomous drone delivery

Senior Mechanical Engineer - Stress Analysis

Materials & StructuresConfirmed live in the last 24 hours
Full-timeSouth San Francisco, CA, USA$145k - $220k

About the Job

Requirements

  • At least 5 years of structural analysis experience for aircraft or complex aerospace vehicles involving metallic, composite, and polymer structures, including hands-on hardware experience.
  • Demonstrated ownership of a top-level Global Finite Element Model (GFEM) or equivalent system-level model integrating multiple subsystem inputs, and experience managing contributions from 3–5 engineers.
  • Capability with industry-standard tools such as NX, FEMAP/NX Nastran, ANSYS, or Siemens Design Center, and proficiency scripting in Python or MATLAB to automate workflows and reports.
  • Classical stress and dynamics background, including Roark/Bruhn-level hand-calculation fluency, structural modes, random vibration, and forced-harmonic analysis.
  • Track record of experimental correlation, including defining instrumentation, producing pre-test predictions, and tuning models to match static, dynamic, or flight tests within engineering tolerances.
  • Clear ownership mentality with rapid decision cadence, tolerance for ambiguity and shifting configurations, disciplined documentation habits, and ability to identify opportunities to maximize cost, scalability, and fleet-health impact.
  • Must be eligible to work in the United States.

Responsibilities

  • Own and maintain the top-level Global Finite Element Model (GFEM), setting and enforcing standards for material properties, numbering, interfaces, model fidelity, and validation procedures, and ensuring it serves as the team's single source of truth.
  • Perform rapid analysis studies and provide design guidance through hand calculations and lightweight beam/shell finite element models to drive design trades; deliver updated models and results within 24–48 hours as configurations evolve.
  • Perform structural sizing and certification support, including static, dynamic, stability, and damage-tolerance analyses for metallic and composite primary and secondary structures; evaluate and optimize flight and ground systems for structural loads, vibration modes, and deflections; and produce documented margin and load reports for qualification testing and regulatory artifacts.
  • Define pre-test predictions, instrumentation plans, and post-test correlation workflows; tune models to test data and drive model agreement within target tolerances, including approximately 5% for stiffness and key stress results for validated modes and load paths.
  • Lead root-cause investigations for test and field failures, generate corrective design changes, and work with manufacturing, design, reliability, and test teams to close actions and update inspection criteria.
  • Collaborate daily with design, systems, reliability, test, and flight operations; create and document standardized in-house finite element tools, verification checklists, and model-release processes; and mentor 3–5 contributors who feed into the GFEM.
  • Support flight-test campaigns and field remediation events on-site, execute rapid test fixes, and prioritize fleet-impacting issues to minimize downtime and preserve flight schedules.
  • Resolve test issues within hours and provide corrective-action direction for issues found in qualification testing.
  • Deliver measurable outcomes including reduced product-level cost per delivery, GFEM release cadence aligned with configuration updates, reduced structural repeat failures across the fleet, mass or margin improvements from design trades, and model-to-test correlation metrics.

About the Company

Zipline

Builds and runs autonomous drone delivery

Zipline builds and operates autonomous drone delivery networks for retailers, restaurants and healthcare systems that need to move products without road traffic. Its electric aircraft carry food, prescriptions and other supplies from partner sites or distribution hubs to customers and health facilities. The company combines aircraft, charging equipment and delivery software with flight operations, so partners buy a logistics service rather than manage their own drones. Merchants use its ordering and tracking tools to reach customers, while governments and health systems contract for medical supply delivery. Zipline was founded in 2014 and has its headquarters in South San Francisco, California.

Company size
1,001-5,000
Company stage
Late Stage VC
Total funding
$3.6B
Headquarters
South San Francisco, CA
Founded
2014

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