Mechanical Engineering Manager, Unmanned Systems (UAV/USV)

Ideal Aerosmith•Rockville, MD

3d•Onsite

About The Position

Ideal Aerosmith is a leading supplier of precision inertial guidance test systems, flight motion simulators, innovative defense solutions in support of the warfighter, and a premier provider of aerospace test engineering services, ATE system engineering, and quality contract manufacturing services to the aerospace industry. We're experts and we earn that title everyday with our customers through innovative engineering, manufacturing, and sustainment of world-class motion and electric test solutions and services. Here, we don’t just solve complex problems - we redefine what’s possible. Every role at Ideal Aerosmith supports a lean culture through continuous improvement - ongoing, incremental enhancements to products, processes, or services aimed at reducing waste and boosting efficiency, customer service, and performance. With a team of skilled problem solvers and a culture that thrives on tackling challenges head-on, we are dedicated to our clients' success. Enjoy competitive benefits, a supportive work environment, and every other Friday off to recharge. The Mechanical Engineering Manager will lead the design, integration, and performance of complex mechanical systems for Ideal Aerosmith’s unmanned platforms, including Unmanned Aerial Vehicles (UAVs) and Unmanned Surface Vehicles (USVs). This role serves as the mechanical system integrator, responsible for ensuring all mechanical subsystems—structures, propulsion integration, thermal systems, launch and recovery systems, and payload accommodations—function as a cohesive, reliable system across development, test, and production environments. This is a hands-on leadership role. The Mechanical Engineering Manager is expected to work side-by-side with the team—on the floor, in the lab, and at test sites—diagnosing issues, simplifying designs, and driving rapid, practical solutions. Combining deep technical leadership with team management responsibilities, this position oversees the full lifecycle of mechanical system development from concept through flight testing and production, ensuring alignment between engineering execution, program goals, and company standards while driving speed, quality, and innovation. This role requires a mindset of extreme ownership. The Mechanical Engineering Manager is accountable not only for the quality of engineering output, but for ensuring that mechanical work progresses at the pace required by the program. This includes proactively identifying priorities, driving clarity in tasking, removing obstacles, and taking responsibility for outcomes across team boundaries. Success in this role is measured by delivered results, not effort or activity.

Requirements

Bachelor’s degree in Mechanical Engineering or a related field.
12+ years of mechanical engineering experience in complex systems, preferably in aerospace, UAV/UAS, or high-performance vehicles.
5+ years of experience in a technical leadership or management role.
Experience designing and integrating structures, propulsion systems, or mechanical subsystems in a fast-paced R&D or prototyping environment.
Demonstrated experience supporting hardware from concept through testing and production.
Ability to travel (domestic and internationally).
Must have valid driver’s license and ability to obtain a passport.
Due to federal contract requirements, candidates must be U.S. citizens, lawful permanent residents, or protected individuals as defined by 8 U.S.C. §1324b(a)(3).

Nice To Haves

Master’s degree preferred.

Responsibilities

Own prioritization and execution of all mechanical engineering tasking, aligning team efforts to program needs and ensuring work is driven to completion on schedule.
Act as the single point of accountability for mechanical deliverables by ensuring tasks are clearly defined, resourced, tracked, and closed.
Drive a results focused execution culture within the mechanical team, aggressively remove blockers across organizational boundaries, escalating when required to maintain momentum.
Lead the design and development of UAV and USV mechanical architectures, including structures, propulsion integration, thermal management, and payload integration.
Manage and mentor a team of mechanical engineers, providing technical guidance, performance feedback, and professional development support.
Own end-to-end mechanical system architecture, ensuring robust, lightweight, and manufacturable designs.
Serve as the mechanical system integrator across all subsystems and external partners.
Define and manage mechanical interfaces (ICDs) across airframe, propulsion, payloads, and ground systems.
Lead system-level trade studies (weight, strength, thermal performance, manufacturability, cost).
Oversee mechanical subsystem development from requirements definition through design, prototyping, integration, testing, and deployment.
Drive rapid prototyping efforts using advanced manufacturing techniques, including additive manufacturing and quick-turn fabrication.
Work hands-on with the team to diagnose failures, troubleshoot integration issues, and implement design improvements during builds and testing.
Review and approve CAD models, drawings, tolerance stacks, and mechanical specifications.
Drive material and component selection decisions with consideration for performance, durability, scalability, and cost.
Partner cross-functionally with electrical, software, manufacturing, and supply chain teams to ensure seamless system integration.
Lead mechanical integration, system bring-up, and troubleshooting during prototype builds, ground testing, and flight testing.
Establish and enforce mechanical engineering standards, design practices, and documentation processes.
Oversee development and execution of verification and validation plans, including structural, thermal, vibration, and environmental testing.
Support production transition, including design for manufacturability (DFM), design for assembly (DFA), cost optimization, and resolution of production issues.
Own mechanical execution against program schedule, proactively identifying risks, driving recovery plans, and ensuring commitments are met.
Contribute to program reviews, risk assessments, and system-level technical decisions.
Drive continuous improvement across engineering processes, tools, and workflows.