Mechanical Engineer - HyperRF

AV is seeking skilled Mechanical Engineers to support the design, analysis, and development of advanced RF and electromechanical systems within the Hyper-RF division. This role is critical to delivering robust, manufacturable, and high-performance products across a range of applications including radar, wireless communications, phased array systems, and embedded electronics.

The ideal candidate brings deep expertise in mechanical design using Solid Works, structural and thermal analysis using Ansys, and a strong working knowledge of product lifecycle management (PLM) processes within a disciplined engineering environment. This individual will work closely with cross-functional teams to transition designs from concept through production while ensuring compliance with quality and documentation standards.
** RESPONSIBILITIES
* * Perform and interpret structural, thermal, and vibration analyses using Ansys AEDT/Mechanical or Solidworks Simulation to validate designs against requirements

Ensure designs meet environmental, performance, and manufacturability requirements Identify, draft, and execute environmental test plans according to system level requirements
** REQUIRED QUALIFICATIONS
** Bachelor’s degree in Mechanical Engineering or related field8+ years of relevant experience in mechanical design and analysis for complex systems

Expert-level proficiency with Solid Works (part modeling, assemblies, drawings, and PDM integration) Strong experience with Ansys for FEA structural analysis (stress, vibration, modal) and CFD thermal analysis (steady-state and transient)
Demonstrated experience designing for ruggedized electronics packaging, including thermal management and structural integrity

Experience with configuration management tools and processes (e.g., PDM/PLM systems, ECO workflows) Experience supporting hardware through full lifecycle (design → build → test → production) Ability to work in a fast-paced, multi-disciplinary team environment
** PREFERRED QUALIFICATIONS
** Experience with RF systems, phased arrays, or high-frequency electronics packaging Familiarity with passive and active thermal management techniques (heatsinks, fans, liquid cooling)
Experience designing for environmental compliance (shock, vibration, thermal cycling, EMI considerations) Knowledge of materials selection for aerospace/defense applications

Experience with MIL-STD environmental and mechanical requirements Familiarity with manufacturing processes (machining, sheet metal, additive manufacturing, injection molding) Experience working in a regulated environment (e.g., ISO 9001, AS9100)
** About AV:
**** AV isn’t for everyone. We hire the curious, the relentless, the mission-obsessed. The best of the best.
** We don’t just build defense technology—we redefine what’s possible. As the premier autonomous systems company in the U.S., AV delivers breakthrough capabilities across air, land, sea, space, and cyber. From AI-powered drones and loitering munitions to integrated autonomy and space resilience, our technologies shape the future of warfare and protect those who serve.

Founded by legendary innovator Dr. Paul Mac Cready, AV has spent over 50 years pushing the boundaries of what unmanned systems can do. Our heritage includes seven platforms in the Smithsonian—but we’re not building history, we’re building what’s next.
** If you're ready to build technology that matters—with speed, scale, and purpose—there’s no better place to do it than AV.*
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