Design & Development Engineer

Job Title:

Design & Development Engineer – R&D

Location:

Salem, NH

• Develop 2D and 3D CAD models of ballistic helmets and associated components and tools. Use CAD tools (Solid Works) to design helmet geometries, accessory interfaces etc.
• Conduct design feasibility studies, FEA simulations, and tolerance analyses.
• Collaborate with industrial designers to balance protection, weight, comfort, and human‑factors requirements.
• Create engineering drawings, BOMs, and design documentation.

• Evaluate and select ballistic materials (UHMWPE, aramid, hybrid composites) based on threat levels and weight/strength trade‑offs.
• Optimize laminate lay‑ups, resin systems, and molding techniques to improve protection and reduce weight.
• Collaborate with suppliers for advanced material development.

• Develop prototypes using molding, lay‑up, and additive manufacturing techniques.
• Coordinate ballistic testing, physical impact testing, and environmental tests according to NIJ, MIL‑STD, and ISO standards.
• Analyze failure modes and refine designs to improve performance and durability.

• Coordinate with certified testing laboratories for ballistic, impact, and environmental performance within regulated safety standards.
• Analyze test results to identify design improvements.

• Work with production teams on tooling design, mold development, and process optimization.
• Improve manufacturability, reduce cost, and ensure repeatable ballistic performance.
• Assist with quality control plans, inspection methods, and process validation.

• Manage development schedules, prototype builds, and test cycles.
• Prepare technical reports, presentations, and documentation for internal and external stakeholders.
• Coordinate with suppliers, labs, and cross‑functional teams.

• Research emerging materials, lightweight structures, and modular helmet technologies.
• Participate in IP development and patent documentation.

• Bachelor's degree in Mechanical Engineering, Materials Engineering or related field.
• Master’s degree preferred (R&D or materials‑focused).

• 2–7+ years of experience in product design or development (defense, composites, PPE, or helmet industry preferred).
• Hands‑on experience with composite manufacturing and ballistic materials.

• Proficiency in CAD tools (Solid Works preferred).
• Some experience with FEA tools (ANSYS, ABAQUS, Hyper Works) for impact and structural simulations.
• Knowledge of composite lay‑up design, molding processes, and material properties.

• Strong problem‑solving and analytical skills.
• Excellent communication and technical writing.
• Ability to work cross‑functionally and across multiple projects.

• Background in military, law‑enforcement PPE development.
• Familiarity with lean manufacturing and DFM/DFA principles.
• Experience with rapid prototyping and CNC machining.

• R&D lab and manufacturing floor environment.
• Occasional travel to testing facilities, affiliate sites, suppliers, or customer sites.

We design and produce life‑critical personal protection solutions for the world’s militaries and first responders. With a portfolio that includes Chemical, Biological, Radiological, Nuclear (“CBRN”) protection. We do this through our two brands, Avon Technologies and Team Wendy. Our mission is to provide unparalleled protection for those who protect us, giving them the confidence to tackle challenging situations and helping them get home safe.

At Avon Protection, we recognize that our success relies on the collective efforts of our talented team. As an organization, we welcome individuals who embody our #FIERCE company values – fearlessness, integrity, excellence, resilience, collaboration, and the ability to execute.

• Flexible Schedule
• Generous paid time off
• Competitive Compensation Package
• Learning and Development Opportunities
• Bonus Plan
• Employee Stock Purchase Plan
• 401(k) Matching
• Tuition Reimbursement Program
• Mentorship Program
• Supplemental plans
• Company‑…