Senior Mechanical Engineer

Senior Mechanical Engineer - Hampton, VA



About the job

Senior Mechanical Engineer - UAS

About Advanced Aircraft Company (AAC)


Do you want to be part of a culture that inspires people to think big, perform with excellence, and build products that matter? At Advanced Aircraft Company (AAC), we design and manufacture high-performance VTOL unmanned aircraft systems (UAS) for defense and commercial applications. As a fast-paced, veteran-owned startup, we are driven by one mission: delivering reliable, high-performance systems that help save the lives of our men and women in uniform. Our work is inspired directly by the warfighter. If you have the passion, courage, and curiosity to solve difficult engineering problems, we invite you to help us build a world defined by Peace Through Strength.

Position Overview


AAC is seeking a Senior Mechanical Engineer with deep intuition and hands-on experience in small UAS (sUAS) design. You will serve as the owner of the complete mechanical CAD assembly, leading the design, fabrication, integration, and sustainment of current and future aircraft hardware from early concept through flight testing and production. This role is highly hands-on, with an emphasis on execution, iteration, and practical engineering judgment in a fast-moving startup environment.

Key Responsibilities

• Mechanical Design Ownership
• Own and maintain the master CAD assembly for AAC aircraft, ensuring high-fidelity models and accurate subsystem integration.
• Manage configuration control and version tracking of all mechanical components.
• End-to-End Product Development
• Execute all stages of the product lifecycle, including concept development, detailed design, analysis, prototyping, flight testing, and manufacturing transition.
• Design and refine composite structures, fuselages, flight surfaces, internal structures, component mounting solutions, propulsion systems, and payload integrations.
• Design Iteration & Manufacturing Optimization
• Redesign aircraft components to optimize manufacturability, reliability, weight, and performance.
• Continuously improve fabrication and assembly processes to support efficient, scalable production (e.g., composite layups, machined parts, 3D-printed structures).
• Technical Leadership
• Serve as the mechanical technical lead, mentoring and guiding other engineers as the team grows.
• Work closely with cross-functional teams to optimize system-level performance against mission requirements.

This is a 90% individual contributor / 10% leadership role, ideal for a senior engineer who leads by doing.

Required Qualifications

• Experience & Expertise
• 10+ years of hands-on mechanical design experience, with deep expertise in small UAS or aerospace systems.
• Proven ability to design lightweight, high-performance flight hardware using sound engineering judgment and intuition.
• Technical Skills
• Proficiency in Autodesk Fusion 360 .
• Strong understanding of aircraft structural design, manufacturing methods, and mechanical integration.
• Strong understanding of latest 3D printing techniques and material selection.
• Communication
• Excellent verbal and written communication skills, with the ability to document designs and communicate technical decisions clearly.
• Eligibility & Location
• U.S. Citizenship required.
• Ability to work on-site at AAC's offices in Hampton, VA .

Desired Characteristics

• Military or Defense Affinity
• U.S. military veteran experience is a strong plus.
• Drone Enthusiast Mentality
• A true "drone nerd" who builds, flies, and experiments with UAS as a hobby.
• Startup Mindset
• Proactive, adaptable, and positive, with the ability to thrive in a fast-paced environment where priorities evolve quickly.
• Research & Documentation
• Strong research and documentation skills to rapidly increase the Technology Readiness Level (TRL) of new designs.