Directed Energy Manufacturing and Process Engineer II

AeroVironment, Inc.; Albuquerque (NM); On-site; USD 75,000 - 114,000; Full time

Benefits offered by this job

Medical insurance

401K with company match

9/80 schedule

Job summary

AeroVironment, Inc. is seeking a Directed Energy Manufacturing and Process Engineer II to develop, implement, and sustain advanced manufacturing processes for complex products and assemblies in a cross-functional environment with Design Engineering, Quality, Supply Chain, and Test Engineering.

You will lead process development, validation, and continuous improvement activities, ensure manufacturability and cost targets, and mentor junior engineers while supporting new product introductions and

Qualifications

• Bachelor's degree in a related engineering field.
• Typically 3–5 years of manufacturing or process engineering experience.
• Experience with NPIs, production transitions, and design-for-manufacturability.
• Ability to read engineering drawings, specs, BOMs.
• U.S. Citizenship and ability to obtain DoD clearance.
• Experience with Lean, Six Sigma, and continuous-improvement methods.

Responsibilities

• Develop, document, validate, and improve manufacturing processes for complex products, assemblies, and test systems.
• Support manufacturing and process engineering activities for new product introduction, design transfers, and production transitions.
• Review product designs for manufacturability, assembly, inspection, serviceability, and cost effectiveness.
• Create and maintain manufacturing documentation (WIs, process specs, SOPs, PFDs, tooling, BOMs).
• Design and implement process improvements using Lean, Six Sigma, root-cause analysis, and other CI methods.
• Support investigations into production problems, nonconformances, yield losses, and process escapes.
• Establish process parameters, acceptance criteria, inspection methods, and production controls.
• Design or coordinate development of fixtures, tooling, gauges, test equipment, and other production aids.
• Support supplier development, component qualification, and outsourced manufacturing processes as needed.
• Provide technical guidance and mentorship to Manufacturing/Process Engineers I and production personnel.

Skills

Lean Manufacturing

Six Sigma

Root-cause analysis

Continuous improvement

Data analysis

Cross-functional collaboration

Problem solving

Communication

Mentoring

Education

Bachelor's degree in Manufacturing Engineering, Mechanical Engineering, Industrial Engineering, Electrical Engineering, or related field

Tools

CAD tools

ERP/MRP/MES/PLM

Job description

Worker Type Regular Job Description Summary The Directed Energy Manufacturing and Process Engineer II is responsible for developing, implementing, optimizing, and sustaining manufacturing processes for complex products and assemblies. This role serves as a technical manufacturing engineering organization, working cross-functionally with Design Engineering, Quality, Supply Chain, Operations, and Test Engineering to improve productivity, quality, cost, safety, and delivery performance. The Manufacturing and Process Engineer II will support process-development and continuous-improvement projects, support Research & Development, New Product Development and Introduction, resolve difficult production issues, and provide technical mentorship to less experienced engineers and manufacturing personnel.

Position Responsibilities

• Develop, document, validate, and improve manufacturing processes for complex products, assemblies, and test systems.
• Support manufacturing and process engineering activities for new product introduction, design transfers, and production transitions.
• Review product designs for manufacturability, assembly, inspection, serviceability, and cost effectiveness.
• Create and maintain manufacturing documentation, including:
  • Work instructions
  • Manufacturing process specifications
  • Standard operating procedures
  • Process flow diagrams
  • Assembly aids and tooling requirements
  • Bills of material and routing information
• Design and implement process improvements using Lean Manufacturing, Six Sigma, root-cause analysis, and other continuous-improvement methodologies.
• Support investigations into production problems, nonconformances, yield losses, and process escapes.
• Help develop corrective and preventive actions and verify their effectiveness.
• Establish process parameters, acceptance criteria, inspection methods, and production controls.
• Design or coordinate the development of fixtures, tooling, gauges, test equipment, and other production aids.
• Support equipment selection, installation, qualification, and maintenance planning.
• Analyze production data to identify trends, constraints, waste, and opportunities for improvement.
• Support process validation activities, including capability studies, first article inspections, qualification testing, and production readiness reviews.
• Partner with Quality Engineering to support root-cause analysis, material review board activities, and corrective-action investigations.
• Support supplier development, component qualification, and outsourced manufacturing processes as needed.
• Provide technical guidance and mentorship to Manufacturing/Process Engineers I and production personnel.
• Ensure processes comply with applicable engineering, quality, safety, environmental, and regulatory requirements.
• Support production operations and troubleshoot urgent manufacturing issues.
• Perform other duties as assigned.

Basic Qualifications (Required Skills & Competencies)

• Bachelor's degree in Manufacturing Engineering, Mechanical Engineering, Industrial Engineering, Electrical Engineering, or a related technical field.
• Typically 3 - 5 years of relevant manufacturing or process engineering experience, or an equivalent combination of education and experience.
• Demonstrated experience developing and sustaining manufacturing processes for complex products or assemblies.
• Experience with new product introduction, production transition, and design-for-manufacturability activities.
• Proven ability to support cross-functional technical projects.
• Strong knowledge of root-cause analysis, corrective action, process capability, and continuous-improvement methods.
• Experience creating and maintaining manufacturing documentation in a controlled environment.
• Ability to read and interpret engineering drawings, specifications, bills of material, and related technical documentation.
• Strong analytical, problem-solving, communication, and organizational skills.
• Ability to work effectively with engineering, operations, quality, supply chain, and external suppliers.
• Proficiency with Microsoft Office or equivalent productivity tools.
• U.S. Citizenship is required
• Ability to obtain and maintain a DoD security clearance

Other Qualifications & Desired Competencies

• Experience with ERP, MRP, MES, PLM, or manufacturing document-control systems.
• Experience with CAD tools and the design of fixtures, tooling, or production aids.
• Experience with automation, robotics, test equipment, or manufacturing systems integration.
• Experience working in aerospace, defense, aviation, medical device, electronics, or another highly regulated manufacturing environment.
• Familiarity with AS9100, ISO 9001, IPC, or other applicable quality standards.
• Experience supporting electromechanical, precision-machined, or highly integrated products.

Core Competencies

• Manufacturing process development
• Design for manufacturability and assembly
• Structured problem solving
• Continuous improvement
• Data analysis and decision-making
• Cross-functional collaboration
• Clear technical communication
• Mentoring and knowledge transfer
• Attention to detail and quality ownership

Physical Demands and Work Environment

Ability to work in an office, engineering laboratory, and manufacturing environment. Ability to wear required personal protective equipment. Ability to occasionally lift, carry, or manipulate materials and equipment within applicable safety limits. Ability to stand, walk, bend, reach, and work around production equipment as required. Ability to support occasional off-shift or extended-hours production activities. Travel may be required based on business needs.

Clearance Level

No Clearance

Salary

The salary range for this role is: $74,500 - $113,500

ITAR Requirement

This position requires access to information that is subject to compliance with the International Traffic Arms Regulations (“ITAR”) and/or the Export Administration Regulations (“EAR”). 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 AeroVironment’s determination that it will be able to obtain an export license in a time frame consistent with AeroVironment’s business requirements. A “U.S. person” 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 § 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.

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 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.

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.

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