Sr. Mechanical Engineer

Job Overview

The Sr. Mechanical Engineer designs, develops, and oversees mechanical systems and components for various projects. They lead engineering teams, manage project timelines, ensure compliance with industry standards, perform technical analysis, and collaborate with cross-functional departments to deliver efficient and reliable mechanical solutions.

Essential Functions

• Investigates, analyzes, plans, designs, develops, implements, tests, to evaluate military weapons systems
• Reviews and prepares engineering and technical analyses, reports, change proposals, and other technical documentation
• Performs system integration, configuration management, quality assurance testing, or acquisition and resource management
• Analyzes designs, develops, implements, tests, or evaluates software, components, or systems related to engineering or functional requirements of military weapons systems, associated support systems, or Leads the execution of complex tasks
• Own mass properties (weight, CG, inertia) and manage configuration trade-offs to meet performance targets
• Design and support tooling, fixtures, and jigs for prototype builds, test, and low-rate production
• Apply DFx principles (DFM, DFA, DFS, DFR) to improve manufacturability, assembly, reliability, serviceability, and cost
• Lead design reviews and cross-functional integration efforts
• Lead rapid prototyping (3D printing, composites, machined parts) and hands-on integration
• Conduct tolerance analysis, basic structural trade studies, and environmental considerations
• Lead build, integration, and flight test activities; rapidly troubleshoot mechanical issues
• Provide mentorship to other members of the team

Standard Essential Functions

• Regular and reliable attendance on a full time basis [or in accordance with posted schedule]
• Responsible for exhibiting professional behavior with both internal and external business associates that reflects positively on the company and is consistent with the company's policies and practices
• Embody AEVEX’s cultural values and align daily actions with department goals and company culture

Qualifications

• Strong ability to performs tasks with little or no guidance
• Familiarity with 2D or 3D engineering design and manufacturing tools (e.g., AutoCAD, ProE or other)
• Strong knowledge of engineering analysis tools (ANSYS, ProMechanica or similar)
• Extremely Proficient with GD&T and engineering drawing standards
• Strong knowledge of Solidworks
• Extremely detail oriented and capable with working in a team environment

Education / Certifications

• Bachelor's Degree in Mechanical Engineering or other related discipline
• Master's Degree Desired

Experience

• 9+ years of mechanical engineering experience
• DoD experience highly preferred
• Experience in SolidWorks, SolidWorks Simulation, AutoCAD, electrical circuit design/troubleshooting, printed circuit board design, reverse engineering techniques, and Microsoft Project
• Experience with computer-aided engineering (CAE) and computer-aided manufacturing (CAM)

Physical Requirements

• Frequently required repetitive movements of wrists, hands, and/or fingers
• Frequently required to sit, and to reach to use computers and other office equipment

Security Clearance

• Ability to obtain/maintain a Top Secret DoD clearance, U.S. Citizenship required

About AEVEX

AEVEX, headquartered in Solana Beach, California, supports the U.S. national security mission and partner nation needs around the world by providing full-spectrum aviation, remote sensing, and analysis solutions. The company's capabilities include custom design and engineering; rapid prototyping; sensor integration and sustainment; aircraft modification and certification; flight test instrumentation and support; mission operations service; advanced intelligence data processing, exploitation, and dissemination solutions; and tailored hardware and software mission-system tools. AEVEX uses agile and customized approaches to rapidly define, develop, and deliver specialized solutions for airborne special mission needs for the U.S. Government, partner nations, and commercial businesses. AEVEX has major offices in California, Florida, North Carolina, Ohio, and Virginia.

AEVEX provides a full suite of comprehensive benefits, including a 401(k)-retirement plan, comprehensive Medical, Dental, Vision, Disability and Life insurance group coverage with a portion of the premiums paid by the company, professional development funds, and an Employee Assistance Plan (EAP) with counseling, legal help, child and elder care support, among other benefits for qualified employees.

Equal Employment Opportunity:

AEVEX is an Equal Opportunity employer. We are committed to providing equal employment opportunities to all employees and applicants without regard to race, religious creed, color, sex (including pregnancy, breast feeding and related medical conditions), gender, gender identity, gender expression, sexual orientation, national origin, ancestry, citizenship status, military and veteran status, marital status, age, protected medical condition, genetic information, physical disability, mental disability, or any other protected status in accordance with all applicable federal, state and local laws.

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