Principal Aerospace Engineer - Multidisciplinary Design, Analysis, and Optimization

Who We Are At Firestorm, we are building the future of expeditionary defense manufacturing and autonomous systems. Modern conflict has exposed a fundamental problem: the systems needed most by operators are often too expensive, too slow to produce, and too difficult to sustain at scale. Firestorm exists to change that. We develop mission-adaptable aerial systems and deployable manufacturing infrastructure designed to put capability directly into the hands of the warfighter. From modular unmanned aircraft to xCell — our deployable microfactory — our goal is to make defense systems rapidly deployable, adaptable, and producible at the point of need. We are looking for builders, operators, and problem-solvers who want to work on meaningful technology with real-world impact. About the Role Firestorm Labs is seeking a highly skilled and motivated Aerospace Engineer to lead the development of our in-house Multidisciplinary Design, Analysis, and Optimization (MDAO) tool. This tool will sit at the heart of how Firestorm designs its next-generation of mission-adaptable unmanned aerial systems, coupling aerodynamics, propulsion, structures, mass properties, stability & control, performance, and cost models into a unified, automated design environment. You will architect the framework, build and integrate the discipline models, and put the tool to work running the trade studies and design optimizations that shape our vehicles. This position requires a deep foundation in aircraft conceptual and preliminary design, coupled with strong software development skills and practical experience building or working within MDAO environments. What You’ll Do Architect, develop, and maintain Firestorm’s MDAO framework (e.g., built on OpenMDAO or a comparable environment), including the underlying data structures, solver strategies, and workflow orchestration. Develop and integrate discipline analysis modules — aerodynamics (vortex-lattice, panel, and CFD-based), propulsion performance decks, structures and mass properties, stability & control, and mission/performance analysis. Build parametric geometry pipelines (e.g., OpenVSP or CAD-integrated) that enable rapid exploration of unconventional UAS configurations. Implement and apply optimization methods including gradient-based and gradient-free optimization, design of experiments, and surrogate modeling. Validate tool outputs against wind tunnel, flight test, and higher-fidelity analysis data, and quantify model uncertainty. Execute vehicle-level trade studies and sizing analyses to support new product development and customer-driven configuration changes. Work cross-functionally with airframe, propulsion, manufacturing, and autonomy teams to ensure the tool reflects real-world design constraints, including additive manufacturing considerations. Establish best practices for version control, testing, documentation, and continuous integration of engineering software. Required Qualifications Bachelor’s degree in Aerospace Engineering or a related field with 8+ years of relevant experience, or a Master’s degree with 6+ years. Strong foundation in aircraft conceptual/preliminary design, aerodynamics, flight performance, and stability & control. Proficiency in Python and experience developing engineering analysis software beyond one-off scripts. Hands-on experience with an MDAO framework (e.g., OpenMDAO, ModelCenter, Dakota, SUAVE) or demonstrated experience building multidisciplinary analysis pipelines. Experience with numerical optimization methods and design space exploration. Ability to operate in fast-paced, iterative development environments. U.S. Person status (Citizen or Permanent Resident) required due to ITAR regulations. Preferred Qualifications Master’s or PhD in Aerospace Engineering with a focus on MDAO, aircraft design, or applied optimization. Experience with tools such as OpenVSP, AVL, XFOIL, SU2, Fluent, STAR-CCM+, or NASTRAN. Experience with surrogate modeling, uncertainty quantification, or gradient-based optimization with analytic derivatives. Prior experience designing small UAS, especially Group 2–3 unmanned aircraft. Familiarity with design for additive manufacturing. Experience with software engineering practices: Git, CI/CD, unit testing, and containerized or HPC compute environments. Work Environment This role is based in San Diego, CA; we welcome applicants who are open to relocating. Relocation assistance is available and may be included in the offer package where appropriate. Must be able to lift up to 25 lbs. and wear appropriate PPE [as required] Willingness to travel up to 25% domestically for field operations, integration events, and testing Compensation US Salary Range: $145,000 – $215,000 USD The posted salary range reflects an estimate based on a variety of compensation factors, including but not limited to relevant experience, education, certifications, specialized skills, geographic location, and business needs. Actual compensation may vary, and this range is subject to change as our compensation structure or market conditions evolve. Benefits & Perks Our culture fosters collaboration, respect, and trust, empowering passionate people to do their best work. We offer a competitive salary, comprehensive benefits, and opportunities for career growth. In addition to an opportunity to take part in an innovative, collaborative and fast-growing business with a highly motivated and skilled team, we also take pride in taking care of our employees. Here are just a few ways that we show our appreciation: We offer comprehensive medical, dental, and visions plans 401(k) Retirement Savings Plan to invest in your long-term retirement goals Equity grants for new hires Unlimited PTO Extremely generous company holiday calendar, including a holiday hiatus in July & December. Generous Parental Leave Lifestyle Spending Account FSA DCFSA HSA Hospital Indemnity insurance Critical Illness insurance Accident insurance Basic Life/AD&D, short-term and long-term disability insurance, 100% covered by Firestorm. Plus, the option to purchase additional life insurance for you and your family. Mental Health Resources: We provide free mental health resources 24/7 including therapy and more. Additional work-life services, such as free legal and financial support, are available to you as well. Export Control Compliance To conform to U.S. government export control regulations, including the International Traffic in Arms Regulations (ITAR) and Export Administration Regulations (EAR), you must be a U.S. citizen, lawful permanent resident of the U.S., protected individual as defined by 8 U.S.C. 1324b(a)(3), or otherwise eligible to obtain the required authorizations from the U.S. Department of State or U.S. Department of Commerce. Equal Opportunity Statement Firestorm is an equal opportunity employer, committed to creating a diverse and inclusive workplace, and upholding equitable hiring practices. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, disability, protected veteran status, or any other characteristic under federal, state, or local law, including those with a criminal history, in a manner consistent with the requirements of applicable state and local laws, including the CA Fair Chance Initiative for Hiring Ordinance. We actively encourage members of recognized minorities, women, Veterans, and those with disabilities to apply, and we work to create a welcoming and supportive environment for all applicants throughout the interview process. Firestorm is committed to fostering an inclusive and accessible work environment. If you require accommodations or assistance during the application process, please don’t hesitate to reach out to us at [email protected] so we can provide the support you need. Compensation The base pay range for this role is $145,000 – $215,000 per year.