Sabre UAV Advanced Mechanical Engineer

General Dynamics Mission Systems, Inc•Manassas, VA

2d•$112,924 - $125,275•Onsite

About The Position

General Dynamics Mission Systems is seeking an Advanced Mechanical Engineer for its Sabre UAV program in Manassas, Virginia. This fully on-site role leads mechanical design and development of UAV structures, payload enclosures, equipment mounts, brackets, mechanisms, and other flight hardware. The engineer creates and reviews 3D CAD models, drawings, bills of material, interface definitions, and geometric dimensioning and tolerancing in accordance with applicable standards, and performs or coordinates structural, thermal, vibration, shock, fatigue, and tolerance analyses to guide design improvements that meet performance and weight targets. The role works across electrical, systems, manufacturing, test, and supplier teams to integrate avionics, wiring, thermal management, environmental protection, and serviceability within platform constraints. It defines and executes mechanical verification and validation, including prototype evaluation, environmental qualification, laboratory testing, flight-test support, and failure investigation. The engineer also contributes to design reviews, configuration management, change control, technical risk management, and communication with program leadership, and supports production transition through design for manufacturability and assembly, supplier coordination, documentation, and resolution of production and field issues. Applicants must be U.S. citizens and be able to obtain and maintain a DoD Secret security clearance; a Secret clearance is preferred at time of hire. The estimated annual salary range is USD $112,924 to $125,275, with actual pay varying based on experience and other factors. The position remains open until filled.

Requirements

Bachelor's degree in Mechanical Engineering, Aerospace Engineering, or a related technical field, or equivalent experience; the posting also describes a bachelor's degree in Mechanical Engineering or a related Science, Engineering, or Mathematics field with at least 5 years of relevant experience, or a master's degree with at least 3 years.
At least 5 years of relevant mechanical design and development experience, consistent with Level 65 classification.
Experience with 3D CAD, mechanical drawings, bills of material, geometric dimensioning and tolerancing, and configuration-controlled engineering data.
Experience with structural and thermal analysis and qualification testing of aerospace, defense, or other safety-critical hardware.
Strong problem-solving, communication, and collaboration skills, with the ability to work across engineering, manufacturing, test, and program teams.
Must be able to obtain and maintain a DoD Secret security clearance; a Secret clearance is preferred at time of hire.
U.S. citizenship is required due to the nature of work performed within the facilities.

Nice To Haves

Experience supporting UAV, airborne, space, or defense hardware programs through design, integration, test, and production.
Familiarity with composite structures, lightweight materials, environmental sealing, thermal management, and vibration or shock isolation.
Experience using ANSYS, NASTRAN, MATLAB, or equivalent structural and thermal engineering tools.
Working knowledge of MIL-STD-810, RTCA DO-160, ASME Y14.5, or similar aerospace and defense design and qualification standards.
Experience with supplier technical oversight, production transition, cost and schedule trade studies, and root-cause corrective action.

Responsibilities

Lead mechanical design and development of UAV structures, payload enclosures, equipment mounts, brackets, mechanisms, and other flight hardware for the Sabre program.
Create and review 3D CAD models, detailed drawings, bills of material, interface definitions, and geometric dimensioning and tolerancing in accordance with applicable engineering standards.
Perform or coordinate structural, thermal, vibration, shock, fatigue, and tolerance analyses; interpret results and drive design improvements that meet performance and weight targets.
Collaborate with electrical, systems, manufacturing, test, and supplier teams to integrate avionics, wiring, thermal management, environmental protection, and serviceability within platform constraints.
Define and execute mechanical verification and validation activities, including prototype evaluation, environmental qualification, laboratory testing, flight-test support, and failure investigation.
Support design reviews, configuration management, change control, technical risk management, and communication of status, issues, and recommendations to program leadership.
Support transition to production through design for manufacturability and assembly, supplier coordination, manufacturing documentation, and resolution of production and field issues.