Senior Mechanical Engineer

## Senior Mechanical Engineer Apply locations:
20521 Seneca Meadows Pkwy, Germantown, MDtime type:
Full time posted on:
Posted 9 Days Agojob requisition :
7791
** Worker Type
** Regular
* * Job Description
**** OVERVIEW
* * AV is seeking skilled Mechanical Engineers to support the design, analysis, and development of electromechanical and opto-mechanical systems for airborne, UAS, and robotic platforms.

The ideal candidate brings deep expertise in mechanical design using Solid Works, structural and thermal analysis using ANSYS (Workbench and Icepak/AEDT), 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 prototype production while ensuring compliance with quality and documentation standards.
** RESPONSIBILITIES
* ** Lead the mechanical design and development of complex assemblies and enclosures for optical, electronic, and motion control (pointing) systems
* Design systems and subassemblies for airworthiness
* Collaborate with subcontractors and customers to define interfaces and oversee design elements and review design artifacts to team's specifications.
* Create detailed 3D models, drawings, and assemblies using Solid Works
* Perform and interpret structural, thermal, and vibration analyses using ANSYS AEDT/Mechanical or Solidworks Simulation to validate designs against requirements
* Collaborate with electrical, optical, and software engineers to ensure seamless system integration
* Drive designs from concept through prototype, qualification, and production
* Develop and maintain complete technical data packages (TDPs), including drawings, BOMs, and analysis artifacts
* Ensure designs meet environmental, performance, and manufacturability requirements
* Support fabrication, prototyping, integration, and test activities, including troubleshooting and root cause analysis
* Participate in and lead design reviews (PDR, CDR, etc.)
* Apply and enforce configuration management best practices, including revision control, change management (ECOs), and traceability
* Mentor junior engineers and contribute to continuous improvement of engineering processes and standards
* Identify, draft, and execute environmental and functional test plans according to system level requirements
** REQUIRED QUALIFICATIONS
*** Bachelor's degree in Mechanical Engineering or related field
* 8+ 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/or CFD thermal analysis (steady-state and transient)
* Demonstrated experience designing for ruggedized electronics packaging, including thermal management and structural integrity
* Demonstrated experience with motion control, robotics, and/or tracking and pointing
* Experience with configuration management tools and processes (e.g., PDM/PLM systems, ECO workflows)
* Strong understanding of GD&T, tolerance stack-ups, and design for manufacturability (DFM)
* 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 precision motion-control systems for pointing, tracking, or stabilization applications (e.g., multi-axis mechanisms, servomechanisms, or robotics).
* Background in integrating mechanical structures with motors and feedback devices (encoders/sensors) to achieve accurate, low-jitter pointing performance in dynamic environments.
* Experience with small UAS (sUAS) mechanical design, including lightweight airframe structures, payload mounting solutions, and integration of mission equipment on rotary-wing platforms.
* Familiarity with passive and active thermal management techniques (heatsinks, fans, liquid cooling)
* Experience designing for environmental compliance (shock, vibration, thermal cycling, EMI considerations) and familiarity with airworthiness principles…