Sr. Mechanical Engineer - Space Technologies

AV provides a full suite of exquisite, space-qualified hardware trusted to fly in the most extreme environments space presents across GEO, MEO, LEO and Cislunar orbits. With hundreds of systems flying in space, our customers turn to AV when a mission can't fail. Our team is expanding to do the big things that have never been done before—the things the nation and the world are counting on us to deliver.

Responsibilities

• Provide engineering design and analysis leadership to diverse R&D programs and small-volume production contracts
• Lead the structural and thermal analysis of mechanical systems for space and airborne hardware
• Work within a multi-disciplined project team
• Responsible for mechanical design and analysis activity, and support integration and formal acceptance-test activities
• Projects vary from packaging high reliability electronics subsystems to opto-mechanical mechanism design such as gimbal and steering mirror systems
• Other duties as assigned

Requirements

• Bachelor's degree in mechanical or aerospace engineering
• 12 years' mechanical engineering experience in one or more of the following areas:
  • Structural and thermal analysis including analytical calculations and FEA (stress analysis, modal analysis, thermal conduction analysis, bolt loads, etc.)
  • Design using CAD software, ideally experience with SolidWorks
  • Tolerance analysis and GD&T practices
  • Space hardware design, analysis, integration, and test
• Strong technical writing skills applicable to engineering documentation (analysis reports, specifications, requirements documents, etc.)

Qualifications

• 15 years' experience in mechanical engineering of space systems
• Strong verbal communication skills needed for customer interaction at design reviews, supplier interaction, etc.
• Ability to quickly adapt to various projects and types of work and to work several projects simultaneously while managing time and priorities
• Ability to work independently or as part of a development team
• Experience and willingness to be hands-on during hardware assembly, integration, and test
• Current US security clearance

Physical Demands

• Ability to work in an office and manufacturing environment (Constant)
• Required to sit and stand for long periods; talk, hear, and use hands and fingers to operate a computer and telephone keyboard (Frequent)

This position requires access to information subject to compliance with the International Traffic Arms Regulations (ITAR) and/or the Export Administration Regulations (EAR). Applicants must qualify as a U.S. person under ITAR and EAR, or be eligible for an export license. A U.S. person includes U.S. citizens, lawful permanent residents (green card holders), refugees, or asylees. Some positions will require current U.S. citizenship due to contract requirements.

Pay

The salary range for this role is $111,500 - $170,000. AeroVironment considers several factors when extending an offer, including location, role and responsibilities, work experience, education/training, and key skills.

Benefits

• Medical, dental, and vision coverage
• 401K with company matching
• 9/80 work schedule
• Paid holiday shutdown

About the Company

AV isn’t for everyone. We hire the curious, the relentless, the mission-obsessed—the best of the best. We don’t just build defense technology—we redefine what’s possible. As the premier autonomous systems company in the U.S., AV delivers breakthrough capabilities across air, land, sea, space, and cyber. From AI-powered drones and loitering munitions to integrated autonomy and space resilience, our technologies shape the future of warfare and protect those who serve.

Founded by legendary innovator Dr. Paul MacCready, AV has spent over 50 years pushing the boundaries of what unmanned systems can do. Our heritage includes seven platforms in the Smithsonian—but we’re not building history, we’re building what’s next.