Zepher Flight Laboratories, Inc. (ZFL) is developing the “Z1”, a 55 pound, 14-foot span VTOL drone that is powered by hydrogen fuel cells. ZFL received a government contract in 2020 to create the Z1 prototype, and a second contract in 2022 to productize and deliver test articles to the U.S. Military. We are looking for engineers, technicians, and operators who are able and willing to push through this next phase with us. Candidates must have a good combination of skill, industry knowledge, curiosity, and drive in order to solve problems effectively and quickly.

Note: Candidates with a variety of skills and experience that fall under multiple job posts (but which may not be a perfect fit for any single one) are encouraged to apply. We'd love to chat.

Summary of Position:

The Composites Manufacturing Engineer will perform ongoing improvements to the carbon fiber airframe of a military 14-foot wingspan carbon fiber prepreg drone. The parts are bladder molded in 2-part metal molds and heated using a hydraulic press. The manufacturing methods have been largely proven out, but further optimization for manufacture is needed. This person must be self-motivated and constantly steer towards creating a manufacturable product.

Working with, and the occasional supervision of, composites technicians is required.

Essential Duties, Responsibilities, and Skills:

• 
  Bachelor's degree in mechanical or aerospace engineering
  
• 2+ years designing composite parts
  
• 2+ years designing composite tooling – metal tooling experience strongly preferred
  
• Strong SolidWorks CAD skills – including working with both surfaces and solids
  
• Experience designing prepreg/bladder-molded parts
  
• Experience performing basic stress and bending calculations of carbon fiber parts consisting of cloth and uni
  
• Ability to define test procedures, execute them, and write concise test reports
  
• This person will take initiative, proactively solve problems, and communicate those actions to their team without supervision.
  
• Good design-for-manufacture (DFM) skills and instincts
  
• Experience creating dimensioned drawings and an understanding of GD&T. This person should have the ability to make manufacturing drawings with only the minimum required definition. This person must be confident enough in their own abilities to resist pressure to over-define parts. They should follow a mantra of: “Quality must be designed in; it cannot be inspected in.”

Preferred Qualifications:

• Experience specifying heated platens and/or hydraulic presses and working with suppliers
• Experience with fixed wing drone composite part design is strongly desired
• A strong understanding of how to design CNC metal parts that can be manufactured on standard CNC mills and CNC lathes with live tooling (design for manufacture)
• Relevant hobbies such as RC aircraft, drones, open-source autopilots, GA aircraft, etc.

This position may require access to information that is subject to compliance with the International Traffic in Arms Regulations (ITAR) and/or the Export Administration Regulations (EAR). To conform to the requirements of the ITAR and/or the EAR, applicant must be a U.S. citizen, lawful permanent resident of the U.S., or protected individual as defined by 8 U.S.C. 1324b(a)(3).

Zepher Flight Labs is an equal opportunity employer. Qualified candidates will be considered for employment regardless of race, color, religion, age, sex, (including pregnancy and gender identity), sexual orientation, political affiliation, national origin, marital status, medical condition, disability, genetic information, parental status, military or Veteran status.

Principals only; no agencies.