Technician III - Hardware Development

Location: 7480 Mission Valley Rd. Suite 101, San Diego, CA 92108 – on-site, regular business hours. U.S. citizenship required.

About the role

We are seeking a highly skilled and motivated Hardware Repair Technician to lead all repairs, warranty, service, and upgrade hardware activities. This role involves handling returned hardware (e.g., under RMA, warranty, or defect management processes), diagnosing, troubleshooting, repairing, and testing units to ensure they meet quality and performance standards. The technician will also upgrade hardware, refurbish units, procure parts, and perform root-cause failure analysis under engineering direction. This position supports the engineering organization and helps maintain throughput in our repair pipeline.

Responsibilities

• Receive, log, and triage incoming hardware returns, defective units, and upgrade requests.
• Perform detailed diagnostics and troubleshooting to isolate faulty subsystems or components (mechanical, electrical, firmware, connectivity, etc.).
• Repair RF assemblies including connectors, cables, wire harnesses, sensors, and mechanical subassemblies.
• Support the production team by performing firmware updates, calibration, alignment, burn-in, and validation testing after repair.
• Collaborate with mechanical, electrical, and systems engineers to obtain schematics, test procedures, engineering change notices (ECNs), and tolerances.
• Implement corrective modifications or retrofits as directed (e.g., engineering change orders).
• Refurbish, rework, or upgrade units per specification or customer request.
• Document repair steps, root causes, and lessons learned; maintain repair logs and databases.
• Provide input to failure analysis and continuous improvement programs.
• Ensure all repairs adhere to quality, safety, and regulatory requirements (e.g., ESD control, cleanroom, certification, internal standards).
• Maintain spare parts, consumables, and tooling inventory relevant to repair operations.
• Suggest process optimizations, tooling improvements, and test fixture enhancements.
• Occasionally assist engineering with prototype debug, mechanical modifications, or system-level integration tasks.

Requirements

• Associate's degree (or equivalent trade school training) in Electrical Engineering, Mechanical Engineering, Robotics Engineering, Mechatronics, or equivalent technical discipline (or strong equivalent hands-on experience).
• At least 5–7 years of experience in hardware repair, technical debugging, or defect analysis in an electronics/systems environment.
• Strong mechanical aptitude: proficient with hand tools associated with electronics unit assembly and repair.
• Strong electronics troubleshooting skills (proficient with multimeters).
• Experience with soldering and connector rework.
• Familiarity with system-level and functional testing.
• Experience reading schematics, block diagrams, mechanical drawings, and understanding system integration.
• Strong understanding of RF principles (frequency, impedance, gain, noise, modulation).
• Ability to isolate mechanical, electrical, and firmware faults and correlate symptoms to root cause.
• Excellent hands-on skills, attention to detail, and methodical approach to debugging.
• Strong documentation, communication, and general computer skills.
• Ability to work closely with engineering staff, accept direction, and follow test procedures and change control.
• Ability to manage multiple repair tasks concurrently and meet throughput goals.
• Commitment to quality, safety, and process discipline (e.g., ESD protocols, clean environment).

Desired Qualifications

• Bachelor's degree in Electrical Engineering, Mechanical Engineering, Robotics Engineering, Mechatronics, or equivalent technical discipline (or strong equivalent hands-on experience).
• Experience with the assembly and repair of ruggedized/hardened computer systems (e.g., MIL-STD, vibration, EMC, harsh environment electronics).
• Experience with failure analysis tools (microscope, thermal imaging).
• Experience with mechanical repair or alignment (e.g., micromechanics, precision assemblies).
• Experience debugging RF electronics systems.
• Familiarity with version control, defect tracking systems, and repair databases.
• Prior exposure to manufacturing test, acceptance test, or field-return programs.
• Certification(s) such as IPC soldering, IPC rework, or other electronics repair credentials.
• Prior work in aerospace, medical, defense, or rugged electronics industries.
• Ability to troubleshoot transmitters, receivers, amplifiers, and RF modules.

Working Conditions & Physical Demands

• Work is primarily in a lab, workshop, or repair bay environment; may include cleanroom or controlled environment conditions.
• Frequent use of test equipment, microscopes, handheld tools, and small part handling.
• Occasional lifting of chassis or assemblies (within safe lift limits).
• May require overtime or flexibility to meet repair deadlines.
• Strict adherence to ESD/control protocols, safety, and quality standards.
• Must be able to lift and maneuver unit assemblies up to 40 lbs and wheeled cases up to 75 lbs.
• May be required to travel CONUS/OCONUS up to 30% as needed.

Pay

The salary range for this role is $33 – $50 per hour. 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 AV

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. If you're ready to build technology that matters—with speed, scale, and purpose—there’s no better place to do it than AV.