Senior Mechanical Engineer

AeroVironment•Germantown, MD

10d•Onsite

About The Position

AV is seeking skilled Mechanical Engineers to support the design, analysis, and development of electromechanical and opto-mechanical systems for airborne, UAS, and robotic platforms. The ideal candidate brings deep expertise in mechanical design using SolidWorks, structural and thermal analysis using ANSYS (Workbench and Icepak/AEDT), and a strong working knowledge of product lifecycle management (PLM) processes within a disciplined engineering environment. This individual will work closely with cross-functional teams to transition designs from concept through prototype production while ensuring compliance with quality and documentation standards.

Requirements

Bachelor's degree in Mechanical Engineering or related field
8+ years of relevant experience in mechanical design and analysis for complex systems
Expert-level proficiency with SolidWorks (part modeling, assemblies, drawings, and PDM integration)
Strong experience with Ansys for FEA structural analysis (stress, vibration, modal) and/or CFD thermal analysis (steady-state and transient)
Demonstrated experience designing for ruggedized electronics packaging, including thermal management and structural integrity
Demonstrated experience with motion control, robotics, and/or tracking and pointing
Experience with configuration management tools and processes (e.g., PDM/PLM systems, ECO workflows)
Strong understanding of GD&T, tolerance stack-ups, and design for manufacturability (DFM)
Experience supporting hardware through full lifecycle (design → build →? test → production)
Ability to work in a fast-paced, multi-disciplinary team environment
ITAR U.S. Citizenship required

Nice To Haves

Experience with precision motion-control systems for pointing, tracking, or stabilization applications (e.g., multi-axis mechanisms, servomechanisms, or robotics).
Background in integrating mechanical structures with motors and feedback devices (encoders/sensors) to achieve accurate, low-jitter pointing performance in dynamic environments.
Experience with small UAS (sUAS) mechanical design, including lightweight airframe structures, payload mounting solutions, and integration of mission equipment on rotary-wing platforms.
Familiarity with passive and active thermal management techniques (heatsinks, fans, liquid cooling)
Experience designing for environmental compliance (shock, vibration, thermal cycling, EMI considerations) and familiarity with airworthiness principles and applicable certification standards for manned and unmanned aircraft systems.
Knowledge of materials selection for aerospace/defense applications
Experience with MIL-STD environmental and mechanical requirements
Familiarity with manufacturing processes (machining, sheet metal, additive manufacturing, injection molding)
Experience working in a regulated environment (e.g., ISO 9001, AS9100)
FAA Part 107 Remote Pilot Certification with sUAS rating

Responsibilities

Lead the mechanical design and development of complex assemblies and enclosures for optical, electronic, and motion control (pointing) systems
Design systems and subassemblies for airworthiness
Collaborate with subcontractors and customers to define interfaces and oversee design elements and review design artifacts to team's specifications.
Create detailed 3D models, drawings, and assemblies using SolidWorks
Perform and interpret structural, thermal, and vibration analyses using ANSYS AEDT/Mechanical or Solidworks Simulation to validate designs against requirements
Collaborate with electrical, optical, and software engineers to ensure seamless system integration
Drive designs from concept through prototype, qualification, and production
Develop and maintain complete technical data packages (TDPs), including drawings, BOMs, and analysis artifacts
Ensure designs meet environmental, performance, and manufacturability requirements
Support fabrication, prototyping, integration, and test activities, including troubleshooting and root cause analysis
Participate in and lead design reviews (PDR, CDR, etc.)
Apply and enforce configuration management best practices, including revision control, change management (ECOs), and traceability
Mentor junior engineers and contribute to continuous improvement of engineering processes and standards
Identify, draft, and execute environmental and functional test plans according to system level requirements