Unlock Innovation in Defense and UAV Technologies with Expert Engineering Leadership
As a seasoned mechanical engineer and hardware leader, I deliver end-to-end solutions for defense-focused hardware and UAV companies. From ruggedized systems and VTOL designs to managing distributed teams, I turn complex challenges into mission-ready products.
- Proven track record delivering reliable hardware on multiple SOCOM contracts and UAV programs.
- Deep technical expertise in electromechanical architecture, UAV design, and end-to-end product development.
- Repeated success leading a distributed hardware team to on-time completion of high-quality products.
About Me
With over a decade of experience in hardware engineering, I've led projects from concept to delivery for organizations like Teal Drones, Ravn, and Vayu. Specializing in defense applications and UAV innovations, I offer hands-on technical services alongside strategic leadership for distributed teams. My work has supported defense contracts, medical delivery UAVs, and high-performance consumer drones.
- 1Mechanical Design and Engineering: Product design (CAD), design for manufacturing (DFM), injection molding, structural analysis, composites, thermal analysis, and rugged enclosures.
- 2UAV/Drone Design and Development: Mission-specific configuration design, airframe structure, aerodynamic analysis, and propulsion sizing. Fixed wing, multi-rotor, and VTOL.
- 3Electromechanical Architecture and Integration: Requirements-based design, system interfaces, electrical systems design, and MIL-STD compliance.
- 4Product Development and Leadership: Requirements definition, vendor management, and team coordination for distributed hardware efforts.
"Sam has been one of the most reliable, capable, and principled employees I have had the privilege of working with... He is a world-class communicator who excels at bridging gaps between executives with differing priorities."
Sam Weiss
Senior Mechanical Engineer
Houston, TX
Tailored Engineering Services for Your Defense or UAV Project
Comprehensive engineering and leadership services to accelerate your hardware development
Technical Engineering Services
Mechanical design, electromechanical architecture, thermal/FEA analysis, composite structure, and rapid prototyping. Ideal for rugged hardware like Compute Pack V2 or VTOL drones like Vayu X5.
Technical Leadership for Distributed Teams
Project management, vendor coordination, requirements gathering, and cross-functional alignment. Proven in leading distributed hardware teams at Ravn for defense contracts, as seen in the Compute Pack V2 and Rail Mounted Controller projects.
Defense-Focused Solutions
Design for rugged environments, Nett Warrior integration, tactical radio integration (PRC-163, Silvus, MPU5), IP-rated enclosures, and tactical integrations, as seen in Tactical Headset and Rail Mounted Controller.
Featured Projects
Recent work demonstrating end-to-end product development and engineering leadership
Compute Pack V2
Led the complete product development of rugged hardware for SOCOM contract.
TealOne Consumer Drone
Led the design of the TealOne drone, including more than 30 unique parts.
Rail Mounted Controller
Developed Rail Mounted Controller (RMC) from HUD interface and drone contol.
Compute Pack Docks
Custom electrical and mechanical design for two generations of docking systems delivering mission data and power to each Compute Pack.
MeshCard - Mobile Meshtastic Node
Designed, assembled, and shipped a sleek Meshtastic mobile node featuring a thin aluminum case.
BluJay Endurance Aircraft
Exceeded mission requirements with 3+ hour endurance.
What Customers Say About Working with Me
Testimonials from leaders in defense and UAV industries
"We've worked with Sam on several R&D projects over the last few years and have been very happy with his work. Sam has very deep knowledge in the UAV field & DFM and has helped us significantly with everything from mechanical and electrical engineering to firmware & management of other vendors & contractors."
David Chen
Head of Research and Development at SkyCatch (from DeltaQuad Testing & Integration project)
LinkedIn"Sam is probably one of the most forthright and honest people I know... His ability to work in composites, 3d printing, CAD, novel materials, and traditional manufacturing processes like high-temperature plastic molds and CNC operations is considerable."
"Sam has the ability to drive to the heart of an engineering problem... He improved upon the previous design, increasing flight time from 1hr to 3hrs and increasing payload capacity."