Senior Mechanical Engineer

Worker Type Regular Job Description AV Titan RF-CUAS Group designs, develops, and manufactures the Titan Counter-Unmanned Aerial System, providing real-time protection for life, property, and sensitive infrastructure from unwanted drones using a non-destructive AI-based approach. Titan systems are deployed across the globe, rapidly expanding the footprint of a technologically innovative solution that addresses all aspects of the user experience. AV is seeking a Senior mechanical engineer with a strong technical background, exceptional mechanical dexterity, and consistent attention to detail. The candidate will be expected to contribute to the design and development of the AV Titan system and related componentsu2014leveraging a familiarity with the design of machined and sheet metal components, 3D printing, cable assemblies, and mechanical assembliesu2014as well as drawing creation thereof. In addition, this personu2019s responsibilities will include performing consistent assembly and disassembly of the Titan system, subassemblies, and external components; this includes diagnosis, troubleshooting, and repair of customer systems. We are seeking a highly motivated individual with strong critical thinking and analytical skills plus strong written and verbal communication skills. The candidate must have demonstrated experience working in a multi-disciplinary environment, be able to quickly adapt to various types of work, and would quickly learn new skills, analysis methods, etc. while supporting a diverse range of tasks. The candidate must be able to multi-task, while supporting technology development programs, along with the rigorous processes & procedures associated with the manufacture of production hardware. A successful candidate would have most (if not all) of the following: + Bacheloru2019s degree in Mechanical Engineering with 5-7+ years of experience in defense or ruggedized system development + Experience designing hardened electro-mechanical enclosures and structural assemblies for harsh operational environments + Working knowledge of MIL-STD requirements (e.g., environmental, shock, vibration, thermal, and sealing standards) + Experience designing for ingress protection (IP/NEMA ratings), EMI shielding, and environmental survivability + Proficiency in thermal management strategies including conduction cooling, heat sinking, forced convection, and interface materials + Experience with structural analysis, tolerance stack-ups, and GD&T practices + Strong capability in developing detailed 2D manufacturing drawings and assembly documentation + Experience supporting environmental qualification testing (shock, vibration, temperature, humidity, salt fog, etc.) + Familiarity with materials selection for military use including corrosion-resistant alloys, coatings, and surface treatments + Experience with cable harness routing, strain relief methods, and connector interface design in high-reliability systems + Hands-on participation in prototype builds, integration, test, and production transition + Experience with configuration management and Product Data Management (PDM) tools + Strong working knowledge of SolidWorks (or equivalent CAD platform) + Ability to work independently or within a small, highly technical team + Demonstrated experience interfacing with suppliers, machine shops, and defense manufacturing partners + Desire for growth into technical leadership or program-level mechanical ownership REQUIRED QUALIFICATIONS + Bacheloru2019s degree in mechanical engineering or equivalent STEM discipline + 5-7+ years of relevant experience with mechanical design and drawing creation + Proven experience developing production-ready mechanical drawings and assemblies + Demonstrated experience working on hardware subject to environmental qualification testing + Proficiency with SolidWorks 3D modeling and 2D drawing creation + Strong attention to detail and commitment to quality and compliance DESIRED QUALIFICATIONS + Active or prior U.S. security clearance (or ability to obtain one) + Familiarity with MIL-STD-810, MIL-STD-461, and related defense standards + Experience designing for EMI mitigation and grounding strategies + Experience with sealed enclosure design, gasket selection, and environmental sealing validation + Experience performing or supporting FEA for structural, vibration, or thermal analysis + Experience supporting full product life-cycle development from concept through sustainment + Experience with rapid prototyping, additive manufacturing, and design for manufacturability (DFM) + Experience operating or supporting CNC machining or fabrication processes + Familiarity with corrosion prevention methods including coatings, platings, and anodization Clearance Level Secret The salary range for this role is: $89,000 - $126,000 AeroVironment considers several factors when extending an offer, including but not limited to, the location, the role and associated responsibilities, a candidateu2019s work experience, education/training, and key skills. ITAR Requirement: _This position requires access to information that is subject to compliance with the International Traffic Arms Regulations (u201cITARu201d) and/or the Export Administration Regulations (u201cEARu201d). 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 AeroVironmentu2019s determination that it will be able to obtain an export license in a time frame consistent with AeroVironmentu2019s business requirements. A u201cU.S. personu201d 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 u00a7 120.15. Some positions will require current U.S. Citizenship due to contract requirements._ 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. For more information about our company benefit offerings please visit: . We also encourage you to review our company website at to learn more about us. Principals only need apply. NO agencies please. About AV: AV isnu2019t for everyone. We hire the curious, the relentless, the mission-obsessed. The best of the best. We donu2019t just build defense technologyu2014we redefine whatu2019s 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 Smithsonianu2014but weu2019re not building history, weu2019re building whatu2019s next. If you're ready to build technology that mattersu2014with speed, scale, and purposeu2014thereu2019s no better place to do it than AV. _We are proud to be an EEO/AA Equal Opportunity Employer, including disability/veterans. AeroVironment, Inc. is an Equal Employment Opportunity (EEO) employer and welcomes all qualified applicants. Qualified applicants will receive fair and impartial consideration without regard to race, sex, color, religion, national origin, age, disability, protected veteran status, genetic data, sexual orientation, gender identity or other legally protected status._ ITAR U.S. Citizenship required. Must be willing to work on government contracts and have the ability to obtain a security clearance. About AV: AV isnu2019t for everyone. We hire the curious, the relentless, the mission-obsessed. The best of the best. We donu2019t just build defense technologyu2014we redefine whatu2019s 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 Smithsonianu2014but weu2019re not building history, weu2019re building whatu2019s next. If you're ready to build technology that mattersu2014with speed, scale, and purposeu2014thereu2019s no better place to do it than AV. Careers at AeroVironment (

Created: 2026-02-26