Summary
Overview
Work History
Education
Skills
Timeline
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James Casserly

San Francisco,CA

Summary

Versatile engineer with 6+ years of experience developing, testing, and integrating complex electromechanical systems at Zipline, the world's leading autonomous drone delivery company. Proven ability to lead mechanical architecture design, execute full-system test plans, and build high-reliability testers that ensure all integrated products meet stringent requirements for airworthiness and performance. My goal as an engineer and designer is to create elegant solutions to complex problems.

Overview

6
6
years of professional experience

Work History

Test Engineer

Zipline Drone Delivery and Logistics
01.2023 - Current
  • Led stress testing campaigns for vehicle door and lid assemblies to characterize torque and payload limitations under worst-case field conditions.
  • Determined the fatigue limits of bonded components and materials through high-cycle endurance testing spanning tens of thousands of operational cycles on many units.
  • Developed and executed automated and manual test sequences for structural, electrical, and environmental validation.
  • Collaborated with robotics engineers to translate AI-driven behaviors into reliable mechanical actions under real-world constraints.

Test Equipment Product Design

Zipline Drone Delivery and Logistics
12.2021 - 01.2023
  • Designed and built scalable, modular test systems for functional validation of avionics, motor controllers, and power systems.
  • Led full lifecycle of test fixture development from concept to deployment across multiple international production sites.
  • Designed robust end-of-line testers that supported multiple years of high-throughput outsourced testing and ensured ease of use, reliability, and compliance with validation protocols.
  • Independently fabricated custom test fixtures and hardware in-house to accelerate development cycles and reduce external dependency

Engineering Technician

Zipline Drone Delivery and Logistics
11.2020 - 12.2021
  • Assembled and validated complete vehicle subsystems including propulsion units, wing structures, and control surfaces.
  • Supported root cause analysis for mechanical and electrical failures; implemented design and process improvements based on findings.
  • Collaborated with engineers to iterate on prototypes and perform mechanical characterization

Manufacturing Technician

Zipline Drone Delivery and Logistics
08.2019 - 11.2020
  • Supported production and assembly of autonomous drones for global deployment.
  • Developed and documented standard operating procedures and provided hands-on training to internal teams and external partners on the assembly of complex, high-precision drone components.
  • Maintained and optimized shop tools and jigs to support consistent build quality and reduce variability.

Product Design Intern

Will Leather Goods
01.2019 - 01.2020
  • Created early-stage product concepts, prototypes, and renderings.
  • Selected materials and designed components for manufacturability and aesthetic appeal.

Education

Bachelor of Arts - Product Design

University of Oregon
Eugene, OR
06-2019

Skills

  • Mechanical System Architecture & Integration
  • Robotics Mechanisms (Actuators, Sensors, Linkages)
  • Test Engineering & Automation
  • CAD (SolidWorks, NX, Fusion 360)
  • Prototyping & Fabrication (3D Printing, Machining)
  • Root Cause Analysis
  • System Testing Under Field-Like Conditions
  • Cross-functional Collaboration (HW, EE, Ops)

Timeline

Test Engineer

Zipline Drone Delivery and Logistics
01.2023 - Current

Test Equipment Product Design

Zipline Drone Delivery and Logistics
12.2021 - 01.2023

Engineering Technician

Zipline Drone Delivery and Logistics
11.2020 - 12.2021

Manufacturing Technician

Zipline Drone Delivery and Logistics
08.2019 - 11.2020

Product Design Intern

Will Leather Goods
01.2019 - 01.2020

Bachelor of Arts - Product Design

University of Oregon

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