Mechanical Engineer - HyperRF

AeroVironment•Germantown, MD

1d•Onsite

About The Position

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. 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. 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. AV isn’t for everyone. We hire the curious, the relentless, the mission-obsessed. The best of the best. We don’t just build defense technology—we redefine what’s possible. As the premier autonomous systems company in the U.S., AV delivers breakthrough capabilities across air, land, sea, space, and cyber. From AI-powered drones and loitering munitions to integrated autonomy and space resilience, our technologies shape the future of warfare and protect those who serve. Founded by legendary innovator Dr. Paul MacCready, AV has spent over 50 years pushing the boundaries of what unmanned systems can do. Our heritage includes seven platforms in the Smithsonian—but we’re not building history, we’re building what’s next. If you're ready to build technology that matters—with speed, scale, and purpose—there’s no better place to do it than AV.

Requirements

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

Nice To Haves

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)

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