Mechanical Engineering DE Analysis, Mid-level to Senior

AeroVironment • Albuquerque, NM

2d

About The Position

AeroVironment is seeking a Mechanical Engineer with a strong engineering analysis background to support the development of advanced directed energy systems. The role focuses on analysis, design, integration, and qualification of complex mechanical and electromechanical hardware for high-performance defense applications. The engineer applies structural, thermal, dynamic, and mechanical engineering principles to systems operating in demanding environments and collaborates with systems, electrical, optical, controls, manufacturing, and test teams to develop designs from concept through production.

The position may be filled at the mid-level or senior level based on the candidate’s experience, technical depth, and leadership. Mid-level engineers independently perform assigned analyses, develop models, document conclusions, and support design decisions, testing, integration, and troubleshooting. Senior engineers lead analysis for complex components, subsystems, or systems; set technical approaches; review analysis work; lead analysis-to-test correlation and discrepancy resolution; and mentor engineers.

The position requires access to information subject to ITAR and/or EAR. Applicants may be asked to provide documentation verifying U.S. person status. U.S. citizenship is required due to the supported Government program; some positions require current U.S. citizenship due to contract requirements. The position also requires the ability to obtain and maintain a U.S. security clearance if required, and compliance with applicable export-control regulations.

Requirements

• Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, or a related technical discipline.
• U.S. citizenship is required due to the Government program supported.
• Mid-level: typically 3 or more years of relevant mechanical engineering and analysis experience.
• Senior-level: typically 7 or more years of relevant experience, including ownership of complex analysis tasks or technical leadership.
• Demonstrated experience with mechanical engineering analysis for complex aerospace, defense, or industrial systems.
• Experience with finite element analysis and structural/thermal mechanics.
• Working knowledge of thermal analysis, vibration, shock, dynamics, and material behavior.
• Experience developing engineering models and documenting analytical methods, assumptions, results, and conclusions.
• Experience correlating analytical predictions with test results or hardware performance.
• Familiarity with mechanical design principles, GD&T, tolerance analysis, materials, and manufacturing processes.
• Experience with SolidWorks and engineering documentation practices.
• Ability to work effectively in a multidisciplinary team environment.
• Strong written, verbal, and technical communication skills.
• Ability to obtain and maintain a U.S. security clearance, if required.
• Ability to comply with applicable export-control regulations, including ITAR requirements.
• Strong fundamentals in mechanics, materials, heat transfer, dynamics, and structural analysis.
• Ability to assess the validity and limitations of analytical models; sound engineering judgment and a methodical approach to problem-solving.
• Ability to convert analysis results into clear, actionable design recommendations.
• Strong attention to detail and technical documentation skills.
• Ability to balance analytical rigor with program cost and schedule objectives.
• Effective collaboration across mechanical, electrical, optical, systems, manufacturing, and test disciplines.
• Ability to work independently on challenging technical problems.
• Commitment to product quality, mission success, and continuous improvement.

Nice To Haves

• Experience with directed energy systems, high-power laser systems, electro-optical systems, precision pointing systems, or stabilized platforms.
• Experience with structural and thermal analysis of high-power electronics, lasers, optical systems, or energy-storage systems.
• Experience using ANSYS, Abaqus, NASTRAN/Patran, or MATLAB.
• Experience with coupled thermal-structural, nonlinear, transient, or dynamic analysis.
• Experience with fatigue, fracture mechanics, damage tolerance, or reliability analysis.
• Experience analyzing airborne, ground, maritime, or other ruggedized defense systems.
• Familiarity with environmental qualification testing and applicable aerospace or military standards.
• Experience with precision mechanisms, gimbals, optical benches, vibration isolation, or alignment-critical assemblies.
• Experience leading analysis reviews, technical investigations, or multidisciplinary development efforts.
• Experience mentoring junior engineers and coordinating work across technical teams.

Responsibilities

• Perform mechanical engineering analysis supporting the design and development of directed energy systems and subsystems.
• Develop, review, and validate models for structural performance, vibration, shock, acoustics, modal response, resonance, thermal management, heat transfer, thermomechanical behavior, fatigue, fracture, durability, loads, stiffness, structural margins, mechanisms, joints, mounts, and precision alignment features.
• Use finite element analysis and other engineering tools to evaluate component and system performance.
• Define analysis assumptions, boundary conditions, material properties, load cases, and acceptance criteria.
• Correlate analytical predictions with test data and update models based on observed hardware performance.
• Conduct trade studies to optimize weight, strength, stiffness, thermal performance, manufacturability, cost, and reliability.
• Support development of mechanical architectures, components, assemblies, and subsystem designs.
• Create and review CAD models, engineering drawings, analysis reports, specifications, and technical presentations.
• Collaborate with design engineers to translate analysis results into practical design improvements.
• Participate in design reviews, requirements development, configuration management, and technical peer reviews.
• Analyze test results, investigate failures or anomalies, and perform root-cause assessments.
• Support prototype fabrication, hardware integration, qualification testing, and transition to production.
• Work with manufacturing, quality, suppliers, and test organizations to resolve technical issues.
• Communicate technical findings and recommendations to engineering leadership and program stakeholders.
• At the senior level, provide technical leadership, mentor engineers, and lead analysis activities for major subsystems or projects.
• At the senior level, establish analysis approaches, methods, requirements, and technical direction; review and approve models, results, assumptions, and reports; and lead resolution of analysis/test discrepancies.
• At the senior level, contribute to program planning, risk management, proposals, and technical strategy.

Benefits

• Medical insurance
• Dental insurance
• Vision insurance
• 401(k) with company matching
• Flexible work schedule options
• Depending on business unit, role, and customer contract requirements, select programs may offer a 9/80 work schedule and paid holiday shutdown.

What This Job Offers

• Job Type: Full-time
• Career Level: Mid Level