Mechanical Engineer - HyperRF

avav; Maryland; On-site; USD 120,000 - 190,000; Full time

Benefits offered by this job

Medical benefits

Dental benefits

Vision benefits

401K with company match

9/80 schedule

Holiday shutdown

Job summary

AV is seeking skilled Mechanical Engineers to support design, analysis, and development of advanced RF and electromechanical systems within the Hyper‑RF division, delivering robust, manufacturable, high‑performance products for radar, wireless, phased array, and embedded electronics.

The ideal candidate has hands‑on SolidWorks, Ansys, and PLM experience, with 8+ years in mechanical design for complex systems, and can drive designs from concept through production while ensuring quality and

Qualifications

• 8+ years of mechanical design and analysis for complex systems.
• Strong proficiency with SolidWorks (part modeling, assemblies, drawings, PDM integration).
• Experience with Ansys for FEA and CFD thermal analysis.
• Design for ruggedized electronics packaging including thermal management.

Responsibilities

• Lead the mechanical design and development of complex assemblies and enclosures for RF and electronic systems.
• Create detailed 3D models, drawings, and assemblies using SolidWorks
• Perform and interpret structural, thermal, and vibration analyses using Ansys, AEDT/Mechanical or SolidWorks Simulation to validate designs
• Collaborate with electrical, RF, FPGA, and software engineers to ensure seamless system integration
• Drive designs from concept through prototype, qualification, and production
• Develop and maintain complete technical data packages (TDPs), including drawings, BOMs, and analysis artifacts
• Ensure designs meet environmental, performance, and manufacturability requirements
• Support fabrication, integration, and test activities, including troubleshooting and root cause analysis
• Participate in and lead design reviews (PDR, CDR, etc.)
• Apply and enforce configuration management best practices, including revision control, change management (ECOs), and traceability
• Work closely with manufacturing and supply‑chain teams to support production readiness and cost optimization
• Mentor junior engineers and contribute to continuous improvement of engineering processes and standards
• Identify, draft, and execute environmental test plans according to system‑level requirements

Skills

8+ years experience

Team collaboration

Fast-paced environment

Education

Bachelor's degree in Mechanical Engineering

Tools

SolidWorks

Ansys

AEDT/Mechanical

SolidWorks Simulation

PDM/PLM

Job description

OVERVIEW

AV is seeking skilled Mechanical Engineers to support the design, analysis, and development of advanced RF and electromechanical systems within the Hyper‑RF division. This role is critical to delivering robust, manufacturable, and high‑performance products across a range of applications including radar, wireless communications, phased array systems, and embedded electronics.

The ideal candidate brings deep expertise in mechanical design using SolidWorks, structural and thermal analysis using Ansys, and a strong working knowledge of product lifecycle management processes within a disciplined engineering environment. This individual will work closely with cross‑functional teams to transition designs from concept through production while ensuring compliance with quality and documentation standards.

RESPONSIBILITIES

• Lead the mechanical design and development of complex assemblies and enclosures for RF and electronic systems
• Create detailed 3D models, drawings, and assemblies using SolidWorks
• Perform and interpret structural, thermal, and vibration analyses using Ansys, AEDT/Mechanical or SolidWorks Simulation to validate designs against requirements
• Collaborate with electrical, RF, FPGA, and software engineers to ensure seamless system integration
• Drive designs from concept through prototype, qualification, and production
• Develop and maintain complete technical data packages (TDPs), including drawings, BOMs, and analysis artifacts
• Ensure designs meet environmental, performance, and manufacturability requirements
• Support fabrication, integration, and test activities, including troubleshooting and root cause analysis
• Participate in and lead design reviews (PDR, CDR, etc.)
• Apply and enforce configuration management best practices, including revision control, change management (ECOs), and traceability
• Work closely with manufacturing and supply‑chain teams to support production readiness and cost optimization
• Mentor junior engineers and contribute to continuous improvement of engineering processes and standards
• Identify, draft, and execute environmental test plans according to system‑level requirements

REQUIRED QUALIFICATIONS

• Bachelor’s degree in Mechanical Engineering or related field
• 8+ years of relevant experience in mechanical design and analysis for complex systems
• Expert‑level proficiency with SolidWorks (part modeling, assemblies, drawings, and PDM integration)
• Strong experience with Ansys for FEA structural analysis (stress, vibration, modal) and CFD thermal analysis (steady‑state and transient)
• Demonstrated experience designing for ruggedized electronics packaging, including thermal management and structural integrity
• Experience with configuration management tools and processes (e.g., PDM/PLM systems, ECO workflows)
• Strong understanding of GD&T, tolerance stack‑ups, and design for manufacturability (DFM)
• Experience supporting hardware through full lifecycle (design → build → test → production)
• Ability to work in a fast‑paced, multi‑disciplinary team environment

PREFERRED QUALIFICATIONS

• Experience with RF systems, phased arrays, or high‑frequency electronics packaging
• Familiarity with passive and active thermal management techniques (heatsinks, fans, liquid cooling)
• Experience designing for environmental compliance (shock, vibration, thermal cycling, EMI considerations)
• Knowledge of materials selection for aerospace/defense applications
• Experience with MIL‑STD environmental and mechanical requirements
• Familiarity with manufacturing processes (machining, sheet metal, additive manufacturing, injection molding)
• Experience working in a regulated environment (e.g., ISO 9001, AS9100)

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 will be asked to provide specific documentation to verify U.S. person status under the ITAR and the EAR. A “U.S. person” according to their definition is a U.S. citizen, U.S. lawful permanent resident (green card holder), or protected individual such as a refugee, asylee. 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.

EEO STATEMENT

We are proud to be an Equal Opportunity Employer, including disability/veterans. AeroVironment, Inc. is an Equal Employment Opportunity 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.

Principals only need apply. NO agencies please.