Sr. 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. Leads and supports the mechanical design, testing, and production of electrical machines as well as the design of electronics packaging for high altitude aerospace applications. Leads or supports mechanical packaging development effort for electronic equipment that withstand stringent environmental requirements (i.e., mass, volume, thermal, vibration). Manages mid-size development projects outsourced to sub-contractors (development of a system, equipment or components).

Position Responsibilities

• Leads or supports the thermal, structural, dynamic, and fluid flow analysis efforts for electronics equipment

• Leads the testing and data collection in the laboratory and the field

• Models the mechanical devices and selects the proper material

• Performs stress and fatigue analysis; Performs thermal analysis and selects bonding material

• Develops mechanical drawings and specifies the dimensional tolerances

• Develops assembly instructions and test procedures

• Develops test plans and test procedures to verify designs

• Works on complex issues where analysis of situations or data requires an in-depth knowledge of variable factors

• Executes team assignments effectively following the given schedule, milestone, and available resources. May coordinate activities of other personnel (Team Lead).

• Other duties as assigned

Basic Qualifications (Required Skills & Experience)

• Minimum 8 – 12 years of relevant technical experience in Mechanical Engineering, of which a minimum of 5 years in developing for production rotating electrical machines, electronics equipment packaging solution, and/or mechanical devices solutions for industrial and aerospace applications

• Experienced in developing requirements specification for mechanical subsystems and according to MIL-STD 961D standard or equivalent

• Has sufficient proficiency with the following CAD /CAE tools to perform one’s position responsibilities:

• SolidWorks and SolidWorks Simulation for mechanical modeling and analysis. (Required)

• ANSYS for structural and fatigue analysis (Preferred)

• ANSYS Icepack for thermal analysis. (Preferred)

• Extensive experience with Solid Works and designing electro-mechanical systems

• Extensive experience with thermal management solutions, tradeoffs, and materials properties

• Experienced with manufacturing methodologies of electrical machines and design for manufacturability

• Injection Molded part design

• Composite structure design

• Experienced with creating and maintaining product document tree

• Experienced with creating and maintaining products bill of materials (BOM)

• Experienced with test and measurement techniques

Other Qualifications & Desired Competencies

• MS degree in Mechanical Engineering is preferred

• Recognition by a reputable international engineering society such as ASME at the senior membership level or higher is desired

• Demonstrates familiarity with MIL-STD-810 or DO-160

• Demonstrates familiarity with MIL-STD 961D standards (or equivalent) for developing subsystem technical specifications

• Demonstrates full understanding & knowledge of engineering principles in the technical discipline and successfully works independently

• Effectively articulates concepts and ideas to both technical and non-technical staff

• 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

• Has effective problem-solving, analytical, interpersonal and communication skills (Verbal and written)

• Focuses on teamwork, collaboration and puts the success of the team above one's own interests

Physical Demands

• Ability to work in an office and production environment (Constant)

• Required to sit and stand for long periods; talk, hear, and use hands and fingers to operate a computer and telephone keyboard (Frequent)

Clearance Level

The salary range for this role is:

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. For more information about our company benefit offerings please visit:

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

Principals only need apply. NO agencies please.

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