Mechanical Engineer, Sr

Sr. Mechanical Engineer

Applies engineering techniques to design, install, modify, analyze, repair and test tools, engines, machines and other mechanically functioning equipment. Leads and supports mechanical design, testing, and production of electrical machines as well as design of electronics packaging for high‑altitude aerospace applications.

Leads or supports mechanical packaging development effort for electronic equipment that withstands stringent environmental requirements. Manages mid‑size development projects outsourced to subcontractors.

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

• 8–12 years of relevant technical experience in Mechanical Engineering, with at least 5 years in developing production rotating electrical machines, electronics equipment packaging solutions, or mechanical device solutions for industrial and aerospace applications.
• Experience developing requirements specifications for mechanical subsystems according to MIL‑STD 961D or equivalent.
• Proficiency with CAD/CAE tools:
  Solid Works for mechanical modeling; ANSYS for structural and fatigue analysis; ANSYS Icepak for thermal analysis.
• Extensive experience designing electrical rotating machines for high‑performance applications.
• Experience with thermal‑management trade‑offs, materials properties, bonding techniques for extreme environmental conditions, and manufacturing methodologies of electrical machines.
• Experience creating and maintaining product document tree, Bill of Materials, and test‑and‑measurement techniques.

• MS degree in Mechanical Engineering preferred.
• Senior membership in a reputable international engineering society (e.g., ASME) desired.
• Familiarity with MIL‑STD‑810 or DO‑160, and with MIL‑STD 961D standards.
• Strong communication and teamwork skills; ability to work in a fast‑paced environment.
• Commitment to continuous learning and performance improvement.

• Work in office and production environments.
• Requires sitting and standing for long periods; use of computer and keyboard.

This position requires access to information that is subject to ITAR and/or EAR. Applicants must qualify as a U.S. person under ITAR and EAR, or obtain export‑license approval. Current U.S. citizenship may be required for certain contract requirements.

Excellent benefits package including medical, dental, vision, 401(k) with company matching, a 9/8‑80 work schedule, and a paid holiday shutdown. For details visit

Aero Vironment (AVAV) is a global leader in unmanned aircraft systems (UAS) and tactical missile systems based in California. Founded in 1971, the company has a proven record of technical innovation.

We are proud to be an Equal Opportunity Employer. All qualified applicants will receive consideration without regard to race, sex, color, religion, national origin, age, disability, veteran status, or any other protected class.

Mid‑Senior

Full‑time

Engineering and Information Technology