Mechanical Engineering Sr. Manager

AeroVironment • San Diego, CA

27d

About The Position

AV’s Titan RF-CUAS Group designs, develops, and manufactures the Titan Counter-Unmanned Aerial System, providing real-time protection for life, property, and sensitive infrastructure from unwanted drones using a non-destructive AI-based approach. Titan systems are deployed across the globe, rapidly expanding the footprint of a technologically innovative solution that addresses all aspects of the user experience. AV is seeking a Mechanical Engineering Sr. Manager to lead our mechanical engineering team and support our growing department. This role is ideal for a mechanically adept engineer with a robust technical background, proven leadership skills, and meticulous attention to detail. The ideal candidate is equally comfortable performing hands-on engineering tasks and managing the development and well-being of direct reports. As Mechanical Engineering Sr. Manager, you will play a dual role: You will be responsible for the supervision, mentorship, and professional development of a multidisciplinary team of Mechanical Engineers and hardware Repair Technicians. Your leadership responsibilities will include team coaching, performance management, resource planning, and fostering a collaborative, high-performance work environment. In addition to management duties, you will contribute hands-on to engineering projects, including the design, development, assembly, troubleshooting, and quality assurance of AV’s Titan system and related products. This requires proficiency with machined and sheet metal component design, 3D printing, cable assemblies, mechanical assemblies, and technical drawing creation.

Requirements

• Minimum of 2-5 years’ experience managing engineering teams, providing supervision, direction, and performance management for a group of 3–5 engineers and/or technicians.
• Demonstrated ability to effectively lead, coach, mentor, and inspire direct reports as well as employees in adjacent workstreams, fostering a culture of collaboration and continuous growth.
• Proven track record in overseeing the transfer of manufacturing knowledge and best practices to contract manufacturing partners, ensuring alignment and quality throughout the supply chain.
• Responsible for driving partnerships with cross-functional teams, aligning tactical execution and strategic initiatives to meet product line objectives.
• Direct oversight and technical guidance in the design of rugged electro-mechanical enclosures and structural assemblies for demanding operational environments.
• In-depth managerial understanding of MIL-STD requirements (environmental, shock, vibration, thermal, and sealing), ensuring team compliance and best practices.
• Leadership in the development of designs that meet ingress protection (IP/NEMA ratings), EMI shielding, and environmental survivability standards.
• Oversight of thermal management strategies deployment, including conduction cooling, heat sinking, forced convection, and interface materials selection.
• Direct management of engineering best practices for structural analysis, tolerance stack-ups, and GD&T, ensuring accuracy across team deliverables.
• Accountability for the development and review of detailed 2D manufacturing drawings and assembly documentation, maintaining high standards and consistency across all outputs.
• Responsible for planning, supporting, and reviewing environmental qualification testing (shock, vibration, temperature, humidity, salt fog, etc.) for team projects.
• Managerial involvement in materials selection processes for military applications, emphasizing corrosion-resistant alloys, coatings, and surface treatments.
• Providing oversight and guidance to cable harness design and routing efforts, including strain relief and connector interface design for high-reliability systems.
• Direct involvement in organizing and overseeing prototype builds, system integration, testing activities, and product transition to production.
• Champion configuration management and Product Data Management (PDM) processes within the team; familiarity with PLM systems is considered an asset.
• Ensure team proficiency with CAD platforms such as SolidWorks, setting best practices and process standards for modeling and design.
• Ability to independently lead a technical team while fostering a collaborative, high-performance environment.
• Manage interactions and relationships with suppliers, machine shops, and defense manufacturing partners, driving quality and schedule adherence.
• Proactively support team members’ growth into technical leadership or program-level mechanical ownership roles.
• Oversee and support CNC machining or fabrication process operations within the team, driving process improvement and quality.
• Ensure the adoption of corrosion prevention methods—such as coatings, platings, and anodization—across all relevant projects and outputs.
• Eligibility to obtain a US Security Clearance.
• Bachelor’s degree in Mechanical Engineering or a related STEM discipline required; advanced degree preferred.
• A minimum of 15 years’ relevant experience in mechanical design, drawing creation, and engineering leadership, preferably within a production or R&D environment.
• Extensive, proven experience overseeing the development and review of production-ready mechanical drawings and assemblies, ensuring compliance with best practices and organizational standards.
• Demonstrated leadership in projects involving hardware that is subject to rigorous environmental qualification testing, managing both technical execution and compliance.
• Highly proficient in SolidWorks (or equivalent CAD software), with experience establishing modeling and drawing standards for engineering teams.
• Exceptional attention to detail, quality mindset, and a strong commitment to compliance, setting an example and ensuring these values are upheld across the department.
• ITAR U.S. Citizenship required.
• Must be willing to work on government contracts and have the ability to obtain a security clearance.

Nice To Haves

• Active or prior U.S. security clearance, or proven ability to obtain one for direct reports and departmental activities.
• Master’s Degree in Mechanical or Systems Engineering; Bachelor’s degree in Mechanical Engineering required.
• In-depth knowledge and managerial application of MIL-STD-810, MIL-STD-461, and associated defense and industry standards within engineering teams.
• Proven experience guiding teams in the design for EMI mitigation and grounding strategies across complex system platforms.
• Demonstrated ability to oversee sealed enclosure design, gasket material selection, and validation of environmental sealing to ensure team deliverables meet or exceed standards.
• Leadership in planning and supporting FEA initiatives for structural, vibration, and thermal analyses, including reviewing and approving team outputs.
• Track record of managing full product life-cycle development efforts—coordinating team activities from initial concept through production, deployment, and sustainment.
• Experience driving department adoption of rapid prototyping, additive manufacturing, and implementing design for manufacturability (DFM) principles across engineering projects.
• Previous experience developing and scaling engineering processes or protocols to improve departmental performance, efficiency, and compliance.
• Recognized ability to build and sustain relationships with cross-functional managers, technical leads, and external stakeholders to achieve project objectives.
• Demonstrated strengths in succession planning and developing high-potential staff for future technical leadership or program management roles within the organization.
• Experience in budgeting, resource allocation, and managing departmental metrics to support engineering deliverables and operational goals.
• Proven success championing continuous improvement initiatives in mechanical engineering quality, process reliability, and organizational best practices.

Responsibilities

• Supervision, mentorship, and professional development of a multidisciplinary team of Mechanical Engineers and hardware Repair Technicians.
• Team coaching, performance management, resource planning, and fostering a collaborative, high-performance work environment.
• Contribute hands-on to engineering projects, including the design, development, assembly, troubleshooting, and quality assurance of AV’s Titan system and related products.
• Proficiency with machined and sheet metal component design, 3D printing, cable assemblies, mechanical assemblies, and technical drawing creation.
• Overseeing the transfer of manufacturing knowledge and best practices to contract manufacturing partners, ensuring alignment and quality throughout the supply chain.
• Driving partnerships with cross-functional teams, aligning tactical execution and strategic initiatives to meet product line objectives.
• Direct oversight and technical guidance in the design of rugged electro-mechanical enclosures and structural assemblies for demanding operational environments.
• Leadership in the development of designs that meet ingress protection (IP/NEMA ratings), EMI shielding, and environmental survivability standards.
• Oversight of thermal management strategies deployment, including conduction cooling, heat sinking, forced convection, and interface materials selection.
• Direct management of engineering best practices for structural analysis, tolerance stack-ups, and GD&T, ensuring accuracy across team deliverables.
• Accountability for the development and review of detailed 2D manufacturing drawings and assembly documentation, maintaining high standards and consistency across all outputs.
• Responsible for planning, supporting, and reviewing environmental qualification testing (shock, vibration, temperature, humidity, salt fog, etc.) for team projects.
• Managerial involvement in materials selection processes for military applications, emphasizing corrosion-resistant alloys, coatings, and surface treatments.
• Providing oversight and guidance to cable harness design and routing efforts, including strain relief and connector interface design for high-reliability systems.
• Direct involvement in organizing and overseeing prototype builds, system integration, testing activities, and product transition to production.
• Champion configuration management and Product Data Management (PDM) processes within the team
• Ensure team proficiency with CAD platforms such as SolidWorks, setting best practices and process standards for modeling and design.
• Manage interactions and relationships with suppliers, machine shops, and defense manufacturing partners, driving quality and schedule adherence.
• Proactively support team members’ growth into technical leadership or program-level mechanical ownership roles.
• Oversee and support CNC machining or fabrication process operations within the team, driving process improvement and quality.
• Ensure the adoption of corrosion prevention methods—such as coatings, platings, and anodization—across all relevant projects and outputs.

Benefits

• AV offers an excellent benefits package including medical, dental vision, 401K with company matching, a 9/80 work schedule and a paid holiday shutdown.

What This Job Offers

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