Principal Mechanical Engineer

Worker Type

Regular

Job Description

Summary

The Sr. Mechanical Engineer applies engineering techniques to design, install, modify, analyze, repair and test tools, engines, machines and other mechanically functioning equipment. This individual will be a part of a design team focused on development of the next generation UAV systems and their subsystems. This includes all levels and facets of design from conceptual clear through the detailed design and will include building and testing of these systems.

Position Responsibilities

• Designs structural components, electro-mechanical design, payload mechanical design, ground equipment mechanical design, launching systems, flight control actuators integration, thermal analysis, prototype hardware development, tooling and fixtures design
• Reads and interprets blueprints, technical drawings, schematics, and computer-generated reports. Assists project managers with the planning and scheduling of engineering work
• Confers with engineers and other personnel to implement operating procedures, resolve system malfunctions, and provide technical information
• Develop manufacturing drawings and bills of materials for components and assembl ies using industry drafting standards
• Researches and analyzes customer design proposals, specifications, manuals, and other data to evaluate the feasibility, cost, and maintenance requirements of designs or applications
• Support design reviews, assist project managers with the planning and scheduling of engineering work, and support manufacturing & suppliers with the production of components & assemblies
• Resolves a wide range of issues in creative ways while applying company policies and procedures. Completes assigned tasks within project schedule and budget
• Demonstrates full understanding of the specialization of role and can research/re-engineer to propose alternate solutions to fairly complex issues
• Works on problems of diverse scope where analysis of data requires evaluation of identifiable factors. Makes decisions that have some impact on project costs and schedule. Provides articulate, accurate instructions and guidance to lower-level Engineers as well as team members outside the department

Basic Qualifications (Required Skills & Experience)

• 5 - 8 years of experience designing complex mechanical systems with demonstrated transition to hardware
• Bachelor’s degree in Mechanical or Aerospace Engineering is required or equivalent combination of education, training and experience.
• Experience in designing the following types of parts: machined parts, simple composite parts, plastic injection molded parts, sheet metal parts, wire assemblies, mechanical assemblies
• Hands‑on building/prototyping experience as it pertains to lightweight miniature robotic systems or similar
• Experience designing electro‑mechanical systems with thermodynamic constraints
• Demonstrated competence in mechanical engineering process and design/analysis tools
• Proven experience in creating engineering drawings in compliance with ASME Y14.100 Engineering Drawing Practices, Y14.5 Dimensioning and Tolerancing, and other applicable ASME Y14 series standards Proficient at Solidworks as well as office software such as MS Office

Other Qualifications & Desired Competencies

• Demonstrates ability to work independently with little supervision. Shares ideas and experiences with others, solicits feedback and asks relevant questions
• Able to excel in a fast‑paced, deadline‑driven environment, where small teams share a broad variety of duties
• Displays strong initiative and drive to accomplish goals and meet company objectives
• Takes ownership and responsibility for current and past work products
• Is committed to learning from mistakes and driven to improve and enhance performance of oneself, others, and the company
• Demonstrates effective problem‑solving, analytical, interpersonal and communication skills. Consistently demonstrates teamwork, collaboration and puts the success of the team above one's own interests

Physical Demands

• Ability to work in an office environment (Constant). Ability to work in a manufacturing environment (Occasional)
• Required to sit and stand for long periods; talk, hear, and use hands and fingers to operate a computer and telephone keyboard (Constant)

Clearance Level

No Clearance

Salary range

The salary range for this role is:

$100,500 - $153,250

AeroVironment considers several factors when extending an offer, including but not limited to, the location, the role and associated responsibilities, a candidate’s work experience, education/training, and key skills.

ITAR Requirement

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”). In order to comply with the requirements of the ITAR and/or the EAR, applicants must qualify as a U.S. person under the ITAR and the EAR, or a person to be approved for an export license by the governing agency whose technology comes under its jurisdiction. Please understand that any job offer that requires approval of an export license will be conditional on AeroVironment’s determination that it will be able to obtain an export license in a time frame consistent with AeroVironment’s business requirements. A “U.S. person” according to the ITAR definition is a U.S. citizen, U.S. lawful permanent resident (green card holder), or protected individual such as a refugee or asylee. See 22 CFR § 120.15. Some positions will require current U.S. Citizenship due to contract requirements.

Benefits

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

We also encourage you to review our company website at to learn more about us.

About AV

AV isn’t for everyone. We hire the curious, the relentless, the mission-obsessed. The best of the best.

We don’t just build defense technology—we redefine what’s possible. As the premier autonomous systems company in the U.S., AV delivers breakthrough capabilities across air, land, sea, space, and cyber. From AI-powered drones and loitering munitions to integrated autonomy and space resilience, our technologies shape the future of warfare and protect those who serve.

Founded by legendary innovator Dr. Paul MacCready, AV has spent over 50 years pushing the boundaries of what unmanned systems can do. Our heritage includes seven platforms in the Smithsonian—but we’re not building history, we’re building what’s next.

If you're ready to build technology that matters—with speed, scale, and purpose—there’s no better place to do it than AV.

We are proud to be an EEO/AA Equal Opportunity Employer, including disability/veterans. AeroVironment, 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.

ITAR

U.S. Citizenship is required. Secret or Top Secret clearance, or the ability obtain a clearance is desired.