Design & Development Engineer

Avon Protection•Salem, NH

7d•$85,000 - $100,000

About The Position

Job Title: Design & Development Engineer – R&D Location: Salem NH Key Responsibilities Product Design & Engineering Develop 2D and 3D CAD models of ballistic helmets and associated components and tools. Use CAD tools (SolidWorks) to design helmet geometries, accessory interfaces etc. Conduct design feasibility studies, FEA simulations, and tolerance analyses. Collaborate with industrial designers to balance protection, weight, comfort, and human-factors requirements. Create engineering drawings, BOMs, and design documentation. Material Research & Performance Optimization Evaluate and select ballistic materials (UHMWPE, aramid, hybrid composites) based on threat levels and weight/strength trade-offs. Optimize laminate lay-ups, resin systems, and molding techniques to improve protection and reduce weight. Collaborate with suppliers for advanced material development. Prototyping & Testing Develop prototypes using molding, lay-up, and additive manufacturing techniques. Coordinate ballistic testing, physical impact testing, and environmental tests according to NIJ, MIL-STD, and ISO standards. Analyze failure modes and refine designs to improve performance and durability. Testing & Validation Coordinate with certified testing laboratories for ballistic, impact, and environmental performance within regulated safety standards . Analyze test results to identify design improvements. Manufacturing Support Work with production teams on tooling design, mold development, and process optimization Improve manufacturability, reduce cost, and ensure repeatable ballistic performance. Assist with quality control plans, inspection methods, and process validation. Project Management Manage development schedules, prototype builds, and test cycles. Prepare technical reports, presentations, and documentation for internal and external stakeholders. Coordinate with suppliers, labs, and cross-functional teams. Innovation & Continuous Improvement Research emerging materials, lightweight structures, and modular helmet technologies. Participate in IP development and patent documentation. Qualifications Education Bachelor's degree in Mechanical Engineering, Materials Engineering or related field. Master’s degree preferred (R&D or materials-focused). Experience 2–7+ years of experience in product design or development (defense, composites, PPE, or helmet industry preferred). Hands-on experience with composite manufacturing and ballistic materials. Technical Skills Proficiency in CAD tools (SolidWorks preferred). Some experience with FEA tools (ANSYS, ABAQUS, HyperWorks) for impact and structural simulations Knowledge of composite lay-up design, molding processes, and material properties. Soft Skills Strong problem-solving and analytical skills. Excellent communication and technical writing. Ability to work cross-functionally and across multiple projects. Preferred Qualifications Background in military, law-enforcement PPE development. Familiarity with lean manufacturing and DFM/DFA principles. Experience with rapid prototyping and CNC machining. Work Environment R&D lab and manufacturing floor environment. Occasional travel to testing facilities, affiliate sites, suppliers, or customer sites. About Avon Technologies: We design and produce life-critical personal protection solutions for the world’s militaries and first responders. With a portfolio that includes Chemical, Biological, Radiological, Nuclear (“CBRN”), protection. We do this through our two brands, Avon Technologies and Team Wendy. Our mission is to provide unparalleled protection for those who protect us, giving them the confidence to tackle challenging situations and helping them get home safe. At Avon Protection, we recognize that our success relies on the collective efforts of our talented team. As an organization, we welcome individuals who embody our #FIERCE company values - fearlessness, integrity, excellence, resilience, collaboration, and the ability to execute. We offer a comprehensive benefits package that includes the following: Flexible Schedule Generous paid time off Competitive Compensation Package Learning and Development Opportunities Bonus Plan Employee Stock Purchase Plan 401k Matching Tuition Reimbursement Program Mentorship Program Supplemental plans Company-paid life and AD&D Medical/Dental/Vision This job description is not intended, and should not be construed, to be an all-inclusive list of all responsibilities, skills, efforts or working conditions associated with this job. While this job description is intended to be an accurate reflection of the job requirements, management reserved the right to modify, add or remove duties from particular jobs and to assign other duties as necessary. Responsibilities of this position may include direct and/or indirect physical or logical access to information, systems, technologies subjected to the regulations/compliance with U.S. Export Control Laws. U.S. Export Control laws and U.S. Government Department of Defense contracts and sub-contracts impose certain restrictions on companies and their ability to share export-controlled and other technology and services with certain "non-U.S. persons" (persons who are not U.S. citizens or nationals, lawful permanent residents of the U.S., refugees, "Temporary Residents" (granted Amnesty or Special Agricultural Worker provisions), or persons granted asylum (but excluding persons in nonimmigrant status such as H-1B, L-1, F-1, etc.) or non-U.S. citizens. To comply with these laws, and in conjunction with the review of candidates for those positions within Avon that may present access to export controlled technical data, Avon must assess employees' U.S. person status, as well as citizenship(s). The questions asked in this application are intended to assess this and will be used for evaluation purposes only. Failure to provide the necessary information in this regard will result in our inability to consider you further for this particular position. The decision whether or not to file or pursue an export license application is at Avon's sole election. Must be legally authorized to work in country of employment without a sponsorship for employment visa status (e.e. H1B status). The anticipated salary range for candidates who will work in Salem, NH is $85,000 to $100,000 annually. The final salary offered to a successful candidate will be dependent on several factors that may include but are not limited to the type and years of experience within the job, type and years of experience within the industry, education, etc. EOE, Including Vet/Disability

Requirements

Bachelor's degree in Mechanical Engineering, Materials Engineering or related field. Master’s degree preferred (R&D or materials-focused).
2–7+ years of experience in product design or development (defense, composites, PPE, or helmet industry preferred).
Hands-on experience with composite manufacturing and ballistic materials.
Proficiency in CAD tools (SolidWorks preferred).
Some experience with FEA tools (ANSYS, ABAQUS, HyperWorks) for impact and structural simulations
Knowledge of composite lay-up design, molding processes, and material properties.
Strong problem-solving and analytical skills.
Excellent communication and technical writing.
Ability to work cross-functionally and across multiple projects.

Nice To Haves

Background in military, law-enforcement PPE development.
Familiarity with lean manufacturing and DFM/DFA principles.
Experience with rapid prototyping and CNC machining.

Responsibilities

Develop 2D and 3D CAD models of ballistic helmets and associated components and tools.
Use CAD tools (SolidWorks) to design helmet geometries, accessory interfaces etc.
Conduct design feasibility studies, FEA simulations, and tolerance analyses.
Collaborate with industrial designers to balance protection, weight, comfort, and human-factors requirements.
Create engineering drawings, BOMs, and design documentation.
Evaluate and select ballistic materials (UHMWPE, aramid, hybrid composites) based on threat levels and weight/strength trade-offs.
Optimize laminate lay-ups, resin systems, and molding techniques to improve protection and reduce weight.
Collaborate with suppliers for advanced material development.
Develop prototypes using molding, lay-up, and additive manufacturing techniques.
Coordinate ballistic testing, physical impact testing, and environmental tests according to NIJ, MIL-STD, and ISO standards.
Analyze failure modes and refine designs to improve performance and durability.
Coordinate with certified testing laboratories for ballistic, impact, and environmental performance within regulated safety standards .
Analyze test results to identify design improvements.
Work with production teams on tooling design, mold development, and process optimization
Improve manufacturability, reduce cost, and ensure repeatable ballistic performance.
Assist with quality control plans, inspection methods, and process validation.
Manage development schedules, prototype builds, and test cycles.
Prepare technical reports, presentations, and documentation for internal and external stakeholders.
Coordinate with suppliers, labs, and cross-functional teams.
Research emerging materials, lightweight structures, and modular helmet technologies.
Participate in IP development and patent documentation.