Mechanical Engineer, Sr

Job Description

Summary
:
The Sr. Mechanical Engineer applies engineering techniques to design, install, modify, analyze, repair and test tools, engines, machines and other mechanically functioning equipment. The role leads and supports the mechanical design, testing, and production of electrical machines as well as the design of electronics packaging for high altitude aerospace applications. It also leads or supports mechanical packaging development for electronic equipment that must withstand stringent mass, volume, thermal, and vibration requirements and manages mid‑size development projects outsourced to subcontractors.

• Leads or supports the thermal, structural, dynamic, and fluid flow analysis efforts for electronics equipment
• Leads the testing and data collection in the laboratory and in the field
• Models the mechanical devices and selects the proper material
• Performs stress and fatigue analysis; performs thermal analysis and selects bonding material
• Develops mechanical drawings and specifies dimensional tolerances
• Develops assembly instructions and test procedures
• Develops test plans and test procedures to verify designs
• Works on complex issues where analysis requires in‑depth knowledge of variable factors
• Executes team assignments effectively following the given schedule, milestones, and available resources; may coordinate activities of other personnel (Team Lead)
• Other duties as assigned

• Minimum 8‑12 years of relevant technical experience in Mechanical Engineering, including at least 5 years developing for production rotating electrical machines, electronics equipment packaging solutions, and/or mechanical device solutions for industrial and aerospace applications
• Experience in developing requirement specifications for mechanical subsystems according to MIL-STD‑961D or equivalent
• Proficiency with Solid Works for mechanical modeling, ANSYS for structural and fatigue analysis, and ANSYS Icepak for thermal analysis
• Extensive experience designing electrical rotating machines for high‑performance applications
• Experience with thermal management trade‑offs, solutions, and material properties
• Experience with bonding techniques for extreme environmental conditions using different adhesives
• Experience with manufacturing methodologies of electrical machines
• Experience creating and maintaining product document trees and bills of materials (BOM)
• Experience with test and measurement techniques such as torque transducer calibration and instrumentation

• MS degree in Mechanical Engineering preferred
• Recognition by a reputable international engineering society such as ASME at senior membership level or higher desired
• Familiarity with MIL‑STD‑810 or DO‑160
• Strong knowledge of engineering principles and ability to work independently
• Excellent communication skills with both technical and non‑technical staff
• Adept at working in a fast‑paced, deadline‑driven environment
• Strong initiative and drive to accomplish goals and meet company objectives
• Ownership and responsibility for current and past work products
• Commitment to continuous learning and improvement
• Effective problem‑solving, analytical, interpersonal, and communication skills
• Team player focused on collaboration and team success

• Ability to work in an office and production environment (constant)
• Required to sit and stand for long periods; frequent use of hands and fingers to operate a computer and telephone keyboard

This position requires access to information subject to compliance with the International Traffic in Arms Regulations (ITAR) and/or Export Administration Regulations (EAR). Applicants must qualify as a U.S. person or be approved for an export license. Certain positions may also require U.S. citizenship due to contract requirements.

AV offers a comprehensive benefits package including medical, dental, vision, 401(k) with company matching, a 9/80 work schedule, and paid holiday shutdowns. For more information, visit our benefits portal.

Aero Vironment, Inc. is an Equal Employment Opportunity (EEO) employer and welcomes all qualified applicants. Qualified applicants will receive fair and impartial consideration without regard to race, sex, color, religion, national origin, age, disability, protected veteran status, genetic data, sexual orientation, gender identity, or other legally protected status.