Principal Missile HW Integration Lead

AeroVironment • Huntsville, AL

3d

About The Position

AV is seeking a Principal Missile Hardware Integration Lead to support development, integration, and production transition of the Next Generation Counter-UAS Missile (NGCM) program. This role will serve as the mechanical architecture and producibility authority responsible for integrating effector subsystems into a fieldable All-Up-Round (AUR) configuration capable of meeting performance, weight, and cost objectives as the program transitions from prototype development into Low-Rate Initial Production (LRIP). The selected candidate will lead hardware integration efforts across missile mechanical systems including deployable mechanisms, control actuation systems (CAS), structural airframe components, electro-mechanical subsystems, and launcher interface hardware. This role will work across engineering, manufacturing, and supply chain organizations to ensure subsystem designs are production-ready and aligned with NGCM Average Unit Production Cost (AUPC) targets.

Requirements

• Bachelor's Degree in Mechanical Engineering or related field
• 15+ years of experience in missile, aerospace, or defense hardware development
• Experience in mechanical design and integration of missile flight hardware including:
• Flight control mechanisms
• Deployable wing or tail systems
• Pyrotechnic or electro-mechanical actuators
• Demonstrated experience supporting development of producible missile or UAV systems
• Experience performing structural, thermal, and tolerance analysis of complex assemblies
• Working knowledge of GD&T and configuration management principles
• Experience working with external suppliers to improve hardware manufacturability
• Experience transitioning prototype hardware to production environments
• ITAR Requirement: This position requires access to information that is subject to compliance with the International Traffic Arms Regulations (“ITAR”) and/or the Export Administration Regulations (“EAR”). In order to comply with the requirements of the ITAR and/or the EAR, applicants must qualify as a U.S. person under the ITAR and the EAR, or a person to be approved for an export license by the governing agency whose technology comes under its jurisdiction. Please understand that any job offer that requires approval of an export license will be conditional on AeroVironment’s determination that it will be able to obtain an export license in a time frame consistent with AeroVironment’s business requirements. A “U.S. person” according to the ITAR definition is a U.S. citizen, U.S. lawful permanent resident (green card holder), or protected individual such as a refugee or asylee. See 22 CFR § 120.15. Some positions will require current U.S. Citizenship due to contract requirements.
• Secret Clearance Level

Nice To Haves

• Experience supporting hypersonic, cruise missile, or C-UAS interceptor programs
• Background in manufacturing or CNC machining processes
• Experience implementing Product Data Management (PDM) protocols
• Familiarity with CAD platforms such as Creo, CATIA, or SolidWorks
• Experience integrating ruggedized hardware for mobile or tactical platforms

Responsibilities

• Serve as mechanical integration lead for NGCM effector hardware across guidance, control, propulsion, and structural subsystems
• Own missile mechanical architecture trades impacting weight, packaging, producibility, and manufacturability
• Lead integration of deployable subsystems including wing and tail mechanisms and control actuation systems
• Drive Design for Manufacturing (DFM) and Design for Assembly (DFA) initiatives to reduce AUR assembly time and unit cost
• Support supplier hardware integration including tolerance stack-ups and subsystem interface management
• Conduct structural and thermal assessments to ensure survivability in shock, vibration, and operational environments
• Lead hardware design reviews including drawing release, GD&T compliance, and configuration management
• Partner with Manufacturing and Supply Chain teams to resolve producibility issues impacting rate production
• Support CAMs and program leadership in managing cost, schedule, and technical performance
• Assist in transitioning NGCM from prototype builds to LRIP production configurations
• Mentor junior engineers in missile hardware design, manufacturing processes, and integration rigor

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