Lead Mechanical Engineer

AeroVironment•Huntsville, AL

About The Position

The Lead Mechanical Engineer applies engineering techniques to design, install, modify, analyze, repair, and test tools, engines, machines, and other mechanically functioning equipment. The role leads and supports mechanical design, testing, and production of electrical machines, as well as electronics packaging for high-altitude aerospace applications. It also leads or supports mechanical packaging development for electronic equipment subject to stringent mass, volume, thermal, and vibration requirements, and manages mid-size development projects outsourced to subcontractors.

Requirements

At least 8 years of relevant technical experience in Mechanical Engineering, including at least 5 years developing for production rotating electrical machines, electronics equipment packaging solutions, and/or mechanical device solutions for industrial and aerospace applications.
Experience developing mechanical subsystem requirements specifications according to MIL-STD 961D or an equivalent standard.
Proficiency with SolidWorks for mechanical modeling sufficient to perform the position’s responsibilities.
Extensive experience with thermal management tradeoffs and solutions, and material properties.
Experience with bonding techniques and different adhesives for extreme environmental conditions.
Experience with manufacturing methodologies for electrical machines.
Experience creating and maintaining product bills of materials (BOMs).
Experience with test and measurement techniques, such as torque transducer calibration and instrumentation.
U.S. citizenship is required.
Must presently hold or be capable of obtaining a U.S. security clearance.
Must qualify as a U.S. person under ITAR/EAR requirements or be eligible for an export license; some positions require current U.S. citizenship due to contract requirements.
Ability to work in office and production environments; ability to sit and stand for long periods and use a computer and telephone keyboard.

Nice To Haves

Master’s degree in Mechanical Engineering.
Recognition by a reputable international engineering society, such as ASME, at senior membership level or higher.
Experience with ANSYS for structural and fatigue analysis.
Experience with ANSYS Icepack for thermal analysis.
Extensive experience with SolidWorks and designing high-performance rotating electrical machines.
Experience creating and maintaining a product document tree.
Familiarity with MIL-STD-810 or DO-160.
Familiarity with MIL-STD 961D or equivalent standards for developing subsystem technical specifications.
Full understanding of engineering principles in the technical discipline and ability to work independently.
Ability to communicate concepts effectively to technical and non-technical staff.
Ability to excel in a fast-paced, deadline-driven environment where small teams share varied duties.
Strong initiative and drive to accomplish goals and meet company objectives.
Ownership and responsibility for current and past work products.
Commitment to learning from mistakes and improving individual, team, and company performance.
Effective problem-solving, analytical, interpersonal, and verbal and written communication skills.
Focus on teamwork and collaboration, putting team success above personal interests.

Responsibilities

Lead or support thermal, structural, dynamic, and fluid-flow analysis for electronics equipment.
Lead testing and data collection in laboratory and field settings.
Model mechanical devices and select appropriate materials.
Perform stress and fatigue analysis.
Perform thermal analysis and select bonding materials.
Develop mechanical drawings and specify dimensional tolerances.
Develop assembly instructions and test procedures.
Develop test plans and procedures to verify designs.
Work on complex issues requiring in-depth analysis of variable factors.
Execute team assignments according to schedules, milestones, and available resources.
May coordinate the activities of other personnel as a Team Lead.
Perform other duties as assigned.