Senior Mechanical Engineer

Position Overview

We are looking for 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.

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

Key Responsibilities

Mechanical Design Ownership

• Own and maintain the master CAD assembly for our client 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.

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.