Mechanical Engineer

Lever, Inc.; Herndon (VA); On-site; USD 120,000 - 185,000; Full time

Benefits offered by this job

Health coverage for you and family

4% 401k match

PTO and Sick Leave

Job summary

Aventra Defense Systems, Inc. is seeking a mid-level Mechanical Engineer to own the design and productization of subsystems for the Piranha high-altitude platform. You will move a subsystem from prototype to field-ready, producible hardware, with hands-on CAD, prototyping, and testing.

You’ll see your hardware fly and operate across extreme conditions. The role requires 3–6 years in mechanical design, proficiency in CAD tools, and US citizenship with ability to obtain security clearance.

Qualifications

• Bachelor's degree in Mechanical Engineering, Aerospace Engineering, or related field
• 3-6 years of industry experience in mechanical design, ideally including high-altitude, pneumatic/fluidic, or release/deployment mechanisms
• Proficiency in CAD tools such as SolidWorks or OnShape, with a demonstrable portfolio of designs you've taken from concept through hardware
• Hands-on prototyping and testing experience
• US Citizen with ability to obtain and maintain security clearance

Responsibilities

• Own the mechanical design of an assigned high-altitude subsystem, building on and leveling up existing prototypes
• Conduct rigorous FEA (structural, thermal, and vibration) to ensure your designs survive extreme temperatures and dynamic loads of high-altitude flight
• Design for reliability, manufacturability (DFM), and cost at the subsystem level
• Experience rapid iteration—design a part in CAD, 3D print it in our shop, and have a finished prototype in days to test
• Run bench-level and field testing to validate performance across extreme environmental and altitude conditions

Skills

CAD Tools

Prototyping

Hands-on testing

Security clearance

Education

Bachelor's degree in Mechanical or Aerospace Engineering

Tools

SolidWorks

OnShape

Job description

About Aventra

Aventra Defense Systems is a defense technology company developing and delivering autonomous aerial systems for the U.S. government and allied partners. We operate at the intersection of advanced hardware, software, and national security — designing, building, and fielding systems that perform in the world’s most demanding environments.

We are a mission-driven team moving at startup speed with defense-grade accountability. Our programs span contracted deliveries, government demonstrations, and ongoing system development — and our pace reflects the urgency of the problems we’re solving.

Position Overview & Key Responsibilities

Position Overview

Aventra Defense Systems is seeking a mid-level Mechanical Engineer to own the design and productization of subsystems within our Piranha high-altitude platform — from early prototype through a field-ready, producible design. This is a hands‑on, individual-contributor role with clear subsystem ownership: you’ll take a specific piece of the system and drive it from where it stands today toward a production‑ready product. Just imagine seeing the hardware you designed flying in the stratosphere.

Key Responsibilities

Subsystem Design

• - Turn product requirements documents into reality! Own the mechanical design of an assigned high‑altitude subsystem, building on and leveling up existing prototypes.
• - Conduct rigorous FEA (structural, thermal, and vibration) to ensure your designs survive the extreme temperatures and dynamic loads of high‑altitude flight.
• - Design for reliability, manufacturability (DFM), and cost at the subsystem level.
• - Experience the joy of rapid iteration—design a part in CAD, 3D print it in our shop, and have a finished prototype in your hands days later to test.
• - Run bench‑level and field testing to validate performance across extreme environmental and altitude conditions utilizing thermal/vacuum chambers and strain gauges to make sure your design works.
• - Design and implement tests across a variety of systems and environments.
• - Peer review other engineers' work.
• - Conduct trade studies to understand the state of the art and industry best practices.

Integration & Test

• - Integrate your subsystems with electrical, aero, and software teams.
• - Assist with flight test instrumentation setup and post‑test data collection.
• - Help maintain test equipment, fixtures, and lab organization.
• - Test your design in the field and watch it fly!

Productization and Manufacturing

• - Drive the transition from a working prototype to a rugged, field‑ready, producible design.
• - Perform detailed tolerance stack‑up analysis and apply GD&T to ensure complex assemblies fit flawlessly every time they come off the line.
• - Identify and resolve manufacturing, sourcing, and reliability bottlenecks before they reach production.
• - Support production handoff and work closely with machinists and external vendors to get your hardware built.

Integration & Iteration

• - Coordinate seamlessly with electrical, software, and aero teams, packaging complex avionics and integrating actuation, control, and sensor feedback interfaces.
• - Assist with flight test instrumentation setup, post‑test data collection, and lab organization.
• - Test your design in the field and watch it fly!
• - Dive into post‑flight test data to root‑cause anomalies, then rapidly incorporate field feedback into iterative design improvements.

Documentation & Process

• - Maintain accurate models, drawings, BOMs, and design documentation
• - Support design review processes and component sourcing research
• - Analyze and learn from failures and document so the organization doesn't have to learn the same lesson twice.

Qualifications

Minimum Qualifications

• - Bachelor's degree in Mechanical Engineering, Aerospace Engineering, or related field
• - 3-6 years of industry experience in mechanical design, ideally including high‑altitude, pneumatic/fluidic, or release/deployment mechanisms
• - Proficiency in CAD tools such as SolidWorks or OnShape, with a demonstrable portfolio of designs you've taken from concept through hardware
• - Hands‑on prototyping and testing experience
• - US Citizen with ability to obtain and maintain security clearance

Preferred Qualifications

• - Experience in aerospace, defense, or other high‑reliability industries
• - Exposure to embedded systems or sensor integration
• - Startup or small‑company experience
• - Familiarity with relevant military standards

$120,000 - $185,000 a year

Compensation Package

• - Competitive salary commensurate with experience
• - Generous health coverage for employee and family, premium fully covered
• - 4% 401k match
• - PTO and Sick Leave

Travel & Work Environment

Travel Requirements

• - Travel up to 25% to customer sites, and field test locations
• - Ability to work in austere field conditions and military operational environments
• - Flexibility to support urgent operational requirements and schedule changes

Work Environment

• - In‑person role based in Herndon, VA
• - Collaborative environment supporting critical national security missions
• - Direct support to warfighter capabilities and mission success

Aventra Defense Systems, Inc is a venture‑backed startup building scalable, precision‑guided capabilities for the next generation of combat. We are assembling a team of engineers and operators who believe in speed, simplicity, and delivering real capability to the field—not just PowerPoint slides.