Soft Structures Engineer

Founded in 2022, Mach Industries is a rapidly growing defense technology company focused on developing next-generation autonomous defense platforms. At the core of our mission is the commitment to delivering scalable, decentralized defense systems that enhance the strategic capabilities of the United States and its allies. With a workforce of approximately 220 employees, we operate with startup agility and ambition.

Our vision is to redefine the future of warfare through cutting-edge manufacturing, innovation at speed, and unwavering focus on national security. We are dedicated to solving the next generation of warfare with lethal systems that deter kinetic conflict and protect global security.

Mach is building the next generation of autonomous defense systems—designed, manufactured, and deployed at speed. Our team operates at the intersection of hardware, software, and mission execution to deliver scalable, decentralized capabilities that deter conflict and strengthen allied advantage.

We are seeking an Soft Structures Engineer to lead the design, analysis, and development of our lighter-than-air (LTA) platforms. This role sits at the core of our vehicle architecture—owning the structural, material, and pressure-driven behavior of balloon-based systems from concept through flight.

You will work hands-on with soft materials, high-performance fabrics, and pressurized systems, translating first-principles physics into manufacturable, flight-ready hardware.

• Own the end-to-end design of balloon envelopes, including geometry, material selection, and structural architecture.

• Perform detailed analysis of pressurized and unpressurized systems, including stress, creep, fatigue, and failure modes.

• Design for manufacturability, including seaming, patterning, joining methods, and production constraints.

• Develop and execute test campaigns (ground + flight) to validate models and iterate rapidly.

• Work cross-functionally with mechanical and manufacturing teams to integrate envelope systems into full vehicles.

• Build internal tools and frameworks for simulation, sizing, and performance prediction.

• Drive rapid iteration cycles from prototype to deployment in a fast-paced environment.

• Experience with soft goods / flexible structures (e.g., fabrics, membranes, composites, inflatables, parachutes, sails, balloons, etc.)

• 1+ years of experience in mechanical engineering, with a focus on designing and prototyping mechanical systems (can be in a professional, hobby or academic setting)

• Strong skills in 3D modeling and CAD tools (e.g., NX, SolidWorks, etc.) for mechanical design and iteration.

• Experience with programming languages (e.g. python, MATLAB, C++) for analytical modeling, simulation and engineering problem-solving.

• Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, Electrical Engineering, or a related field.

• Demonstrated experience owning hands-on, end-to-end hardware development efforts (e.g., FSAE, DBF, Rocket Team, or similar projects).

• Background in high-altitude or atmospheric systems.

• Familiarity with textile engineering, coatings, or permeability/diffusion modeling.

• Experience designing for extreme environments (thermal, UV, pressure cycling).

• Knowledge of seaming, bonding, and joining techniques (RF welding, heat sealing, adhesives, stitching) and their structural implications.

• Experience modeling or testing membrane structures under load, including wrinkling, creep, and long-term deformation

• Familiarity with coatings and barrier layers, including permeability, gas retention, and environmental degradation (UV, moisture, temperature cycling)

Disclosures

This position may require access to information protected under U.S. export control laws and regulations, including the Export Administration Regulations (EAR) and the International Traffic in Arms Regulations (ITAR).  Please note that any offer for employment may be conditioned on authorization to receive software or technology controlled under these U.S. export control laws and regulations without sponsorship for an export license.

Mach participates in E-Verify and will provide the federal government with your Form I-9 information to confirm that you are authorized to work in the U.S.

The salary range for this role is an estimate based on a wide range of compensation factors, inclusive of base salary only. Actual salary offers may vary based on (but not limited to) work experience, education and training, critical skills, and business considerations. Highly competitive equity grants are included in most offers and are considered part of Mach’s total compensation package. Mach offers benefits such as health insurance, retirement plans, and opportunities for professional development.

Mach is an equal opportunity employer committed to creating a diverse and inclusive workplace. All qualified applicants will be treated with respect and receive equal consideration for employment without regard to race, color, creed, religion, sex, gender identity, sexual orientation, national origin, disability, uniform service, Veteran status, age, or any other protected characteristic per federal, state, or local law, including those with a criminal history, in a manner consistent with the requirements of applicable state and local laws. If you’d like to defend the American way of life, please reach out!