Senior Mechanical Engineer

Overview

AV is seeking a skilled Mechanical Engineer to support the design, analysis, and development of electromechanical and opto‑mechanical systems for airborne, UAS, and robotic platforms.

• 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 review design artifacts to team 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

• 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

• 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 and applicable certification standards for manned and unmanned aircraft systems
• 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)
• FAA Part
  107 Remote Pilot Certification with sUAS rating
• Clearance Level: No Clearance

AV offers an excellent benefits package including medical, dental, vision, 401K with company matching, a 9/80 work schedule and a paid holiday shutdown.

Salary range: $105,000 – $148,575.

This position requires access to information that is subject to compliance with the International Traffic Arms Regulations (ITAR) and/or the Export Administration Regulations (EAR). Applicants must be a U.S. person under the ITAR or EAR, or a person approved for an export license.

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.