Mechanical Engineer

About

AV is seeking skilled Mechanical Engineers to support the design, analysis, and development of advanced RF and electromechanical systems within the Hyper-RF division. This role is critical to delivering robust, manufacturable, and high-performance products across a range of applications including radar, wireless communications, phased array systems, and embedded electronics.

The ideal candidate brings deep expertise in mechanical design using SolidWorks, structural and thermal analysis using Ansys, and a strong working knowledge of product lifecycle management (PLM) processes within a disciplined engineering environment. This individual will work closely with cross-functional teams to transition designs from concept through production while ensuring compliance with quality and documentation standards.

Responsibilities

• Lead the mechanical design and development of complex assemblies and enclosures for RF and electronic systems
• Create detailed 3D models, drawings, and assemblies using SolidWorks
• Perform and interpret structural, thermal, and vibration analyses using Ansys AEDT/Mechanical or Solidworks Simulation to validate designs against requirements
• Collaborate with electrical, RF, FPGA, and software engineers to ensure seamless system integration
• Drive designs from concept through prototype, qualification, and production
• Develop and maintain complete technical data packages (TDPs), including drawings, BOMs, and analysis artifacts
• Ensure designs meet environmental, performance, and manufacturability requirements
• Support fabrication, integration, and test activities, including troubleshooting and root cause analysis
• Participate in and lead design reviews (PDR, CDR, etc.)
• Apply and enforce configuration management best practices, including revision control, change management (ECOs), and traceability
• Work closely with manufacturing and supply chain teams to support production readiness and cost optimization
• Mentor junior engineers and contribute to continuous improvement of engineering processes and standards
• Identify, draft, and execute environmental test plans according to system level requirements

Required Qualifications

• Bachelor’s degree in Mechanical Engineering or related field
• 8+ years of relevant experience in mechanical design and analysis for complex systems
• Expert-level proficiency with SolidWorks (part modeling, assemblies, drawings, and PDM integration)
• Strong experience with Ansys for FEA structural analysis (stress, vibration, modal) and CFD thermal analysis (steady-state and transient)
• Demonstrated experience designing for ruggedized electronics packaging, including thermal management and structural integrity
• Experience with configuration management tools and processes (e.g., PDM/PLM systems, ECO workflows)
• Strong understanding of GD&T, tolerance stack-ups, and design for manufacturability (DFM)
• Experience supporting hardware through full lifecycle (design → build → test → production)
• Ability to work in a fast-paced, multi-disciplinary team environment

Preferred Qualifications

• Experience with RF systems, phased arrays, or high-frequency electronics packaging
• Familiarity with passive and active thermal management techniques (heatsinks, fans, liquid cooling)
• Experience designing for environmental compliance (shock, vibration, thermal cycling, EMI considerations)
• Knowledge of materials selection for aerospace/defense applications
• Experience with MIL-STD environmental and mechanical requirements
• Familiarity with manufacturing processes (machining, sheet metal, additive manufacturing, injection molding)
• Experience working in a regulated environment (e.g., ISO 9001, AS9100)

This is a pipeline requisition posted in advance of approved headcount for future hiring needs.

Note: Our team is always interested in speaking with exceptional candidates though please note this is a Pipeline posting with more of an eye towards our future needs rather than necessarily being an immediate hire. Only qualified candidates will be contacted.

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 will be asked to provide specific documentation to verify U.S. person status under the ITAR and the EAR. A “U.S. person” according to their 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: http://www.avinc.com/myavbenefits.

We also encourage you to review our company website at http://www.avinc.com to learn more about us.

Principals only need apply. NO agencies please.

Who We Are

Based in California, AeroVironment (AVAV) is a global leader in unmanned aircraft systems (UAS) and tactical missile systems. Founded in 1971 by celebrated physicist and engineer, Dr. Paul MacCready, we’ve been at the leading edge of technical innovation for more than 45 years. Be a part of the team that developed the world’s most widely used military drones and created the first submarine-launched reconnaissance drone, and has seven innovative vehicles that are part of the Smithsonian Institution’s permanent collection in Washington, DC.

Join us today in developing the next generation of small UAS and tactical missile systems that will deliver more actionable intelligence to our customers so they can proceed with certainty – and succeed.

What We Do

Building on a history of technological innovation, AeroVironment designs, develops, produces, and supports an advanced portfolio of unmanned aircraft systems (UAS) and tactical missile systems. Agencies of the U.S. Department of Defense and allied military services use the company’s hand-launched UAS to provide situational awareness to tactical operating units through real-time, airborne reconnaissance, surveillance, and target acquisition.

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