Mechanical Engineer II​/III; UAV​/USV

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Full Time Rockville, MD, US

5 days ago Requisition

Ideal Aerosmith is a leading supplier of precision inertial guidance test systems, flight motion simulators, innovative defense solutions in support of the warfighter, and a premier provider of aerospace test engineering services, ATE system engineering, and quality contract manufacturing services to the aerospace industry. We're experts and we earn that title everyday with our customers through innovative engineering, manufacturing, and sustainment of world-class motion and electric test solutions and services.

Here, we don’t just solve complex problems - we redefine what’s possible. Every role at Ideal Aerosmith supports a lean culture through continuous improvement - ongoing, incremental enhancements to products, processes, or services aimed at reducing waste and boosting efficiency, customer service, and performance. With a team of skilled problem solvers and a culture that thrives on tackling challenges head-on, we are dedicated to our clients’ success.

Enjoy competitive benefits, a supportive work environment, and every other Friday off to recharge.

The Mechanical Engineer II/III independently contributes to the design, development, and integration of mechanical systems for Ideal Aerosmith’s Unmanned Aerial Vehicles (UAVs) and Unmanned Surface Vehicles (USVs). This role owns defined components or subsystems and balances performance, cost, weight, and manufacturability within aggressive development timelines. The Mechanical Engineer II demonstrates sound engineering judgment, strong problem‑solving skills, and comfort working across design, prototyping, and test activities.

• Design mechanical components and subsystems for UAVs and USVs, including propulsion‑adjacent hardware, structural elements, and payload interfaces.
• Develop detailed CAD models, drawings, and complete engineering documentation packages.
• Perform mechanical analyses (e.g., structural, thermal, vibration) to support design validation and trade studies.
• Support prototype builds and lead mechanical integration activities.
• Collaborate with manufacturing teams to optimize designs for cost, quality, and producibility.
• Develop and execute mechanical test plans to validate performance, durability, and environmental robustness.
• Identify technical risks and implement mitigation strategies.
• Support supplier engagement related to materials, fabrication methods, and component sourcing.

• Bachelor’s degree in Mechanical Engineering or related field.
• 3+ years of relevant experience (internships/co‑ops applicable).
• Ability to travel (domestic and internationally).
• Must have valid driver’s license and ability to obtain a passport.
• Due to federal contract requirements, candidates must be U.S. citizens, lawful permanent residents, or protected individuals as defined by 8 U.S.C. §1324b(a)(3).

• Strong mechanical design and analysis skills.
• Experience with CAD and engineering simulation tools.
• Familiarity with manufacturing processes, including machining and additive manufacturing.
• Understanding of lightweight structures and packaging constraints.
• Ability to troubleshoot mechanical issues during build and test activities.
• Effective written and verbal communication skills and cross‑functional collaboration ability.

• Must have the ability to lift and/or carry 45 lbs.
• Ability to work for extended periods at computer workstation/keyboard.
• Ability to type accurately and efficiently.
• The position will require walking, standing, squatting, crouching, stooping, lifting, climbing, pulling, pushing, sitting, repetitive motion and kneeling.

Salary Range: $85,000-$115,000 annually.

This salary range represents a good faith estimate of the base compensation for this position. Actual base compensation will be determined based on multiple factors, including location, the scope and responsibilities of the position, the candidate’s qualifications, internal…