Principal Mechanical Engineer (UAV/USV)

Ideal Aerosmith•Rockville, MD

8d•$110,000 - $200,000

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 Principal Mechanical Engineer will participate in the design and rapid prototyping of engines and other mechanical systems for Unmanned Aerial Vehicles (UAVs) and Unmanned Surface Vehicles (USVs). It requires expertise in lightweight, cost-effective engine design and advanced manufacturing methods such as additive manufacturing, 3D printing, and other innovative production techniques. The focus will be on developing engines that meet performance requirements while ensuring supply chain reliability, scalability, and cost efficiency. In addition to propulsion systems, the role will contribute to other mechanical innovations, including catapult launch systems and payload integrations, in close collaboration with Ideal Aerosmith’s aerospace and engineering teams. This position is a key technical contributor for Ideal Aerosmith’s next-generation unmanned and autonomous defense systems portfolio. This position bridges innovation and execution - ensuring every prototype, system integration, and flight test directly contributes to validated, deployable capability for distributed maritime and joint-force operations.

Requirements

Bachelor's degree in Mechanical Engineering or a related field. Master's degree preferred.
15+ years of experience in mechanical engineering, with a focus on engine design and prototyping, preferably in the aerospace or automotive industry.
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).
Strong understanding of thermodynamics, fluid mechanics, and propulsion systems.
Proficiency in CAD software (e.g., SolidWorks, CATIA) and simulation tools (e.g., ANSYS, MATLAB).
Experience with advanced manufacturing techniques such as additive manufacturing, 3D printing, and rapid prototyping.
Strong analytical skills and problem-solving abilities, with a keen attention to detail.
Excellent communication skills, with the ability to effectively collaborate with multidisciplinary teams and stakeholders.
Ability to thrive in a fast-paced, dynamic environment and adapt to changing priorities and project requirements.
Ability to travel (domestic and internationally).
Must have valid driver’s license and ability to obtain a passport.
Must have the ability to lift and/or carry 45 lbs.
Ability to work for extended periods at computer workstation/keyboard.
Ability to type accurately and efficiently.
The position will require walking, standing, squatting, crouching, stooping, lifting, climbing, pulling, pushing, sitting, repetitive motion and kneeling.

Nice To Haves

Master's degree preferred.

Responsibilities

Participate in the design and development of engines for UAVs and USVs, focusing on lightweight, low-cost solutions that can be rapidly manufactured using advanced manufacturing techniques.
Collaborate closely with cross-functional teams, including aerospace engineers, electrical engineers, and industrial engineers, to ensure seamless integration of engines with vehicle components.
Conduct thorough analysis and simulation to optimize engine performance, efficiency, and reliability under various operating conditions.
Design engine components and subsystems using CAD software, ensuring compliance with performance requirements and industry standards.
Implement advanced manufacturing techniques such as additive manufacturing and 3D printing to fabricate engine components, optimizing for speed and scalability.
Develop and implement innovative production solutions and manufacturing processes to facilitate rapid and cost-effective production of engines.
Lead and contribute to other unmanned vehicle projects including but not limited to payload integration, launch systems, and structural analysis for cost and manufacturability.
Work closely with suppliers and vendors to secure reliable and high-quality materials and components, while optimizing costs and lead times.
Provide technical guidance and support to junior engineers and production staff, fostering a culture of innovation, collaboration, and continuous improvement.