Mechanical Engineer - Multiple Levels

AeroVironment, Inc.; Albuquerque (NM); On-site; USD 75,000 - 160,000; Full time

Benefits offered by this job

Health insurance

Life insurance

Disability coverage

Paid time off and holidays

Parental leave

401(k) matching

Job summary

AeroVironment, Inc. seeks a Mechanical Engineer to design and analyze mechanical components and systems for RF and electromechanical platforms.

Onsite roles in Albuquerque, NM or Germantown, MD involve hands-on hardware, prototyping, and cross-functional collaboration with RF, electrical, software, and manufacturing teams. Responsibilities include creating CAD models, performing structural/thermal analyses, and contributing to the product lifecycle from design through field support.

Qualifications

• Bachelor’s degree in mechanical engineering or related discipline.

Responsibilities

• Design and develop mechanical components, assemblies, enclosures, chassis, fixtures, payloads, and support equipment for advanced RF and electromechanical systems.

Skills

Mechanical design

Thermal analysis

Structural analysis

GD&T

3D CAD (SolidWorks)

Engineering documentation

Cross-functional teamwork

Problem solving

Security clearance readiness

Education

Bachelor’s degree in mechanical engineering

Tools

ANSYS

SolidWorks

SolidWorks Simulation

Job description

Worker Type Regular Job Description Summary

Join AV and help build the next generation of mission-critical RF and electromechanical systems. We are seeking talented Mechanical Engineers to work onsite at one of our Albuquerque, New Mexico, or Germantown, Maryland, offices, supporting the design, analysis, integration, and testing of advanced technologies for critical aerospace and defense missions. At AV, you will work alongside experienced engineers and cross‑functional teams to solve challenging technical problems and transform innovative concepts into reliable, manufacturable products. Our Mechanical Engineers contribute across the full product lifecycle from early‑stage design and analysis through prototyping, qualification, production, and field support. Whether your expertise is in mechanical design, thermal analysis, structural analysis, electronics packaging, or integration and test, AV offers opportunities to make a meaningful impact while expanding your technical skills. You will work with modern engineering tools, gain hand‑on experience with real hardware, and contribute to products where performance, quality, and mission success matter. If you are passionate about engineering, enjoy solving complex problems, and want to see your work make a difference, we invite you to join AV and grow your career with us.

Position Responsibilities

• Design and develop mechanical components, assemblies, enclosures, chassis, fixtures, payloads, and support equipment for advanced RF and electromechanical systems.
• Create and maintain SolidWorks or similar CAD models, assemblies, drawings, bills of materials, and configuration‑controlled technical documentation.
• Perform or support structural, thermal, vibration, and tolerance analyses using ANSYS, SolidWorks Simulation, or comparable tools.
• Apply GD&T, tolerance analysis, design‑for‑manufacturability, and design‑for‑assembly principles.
• Develop electronics‑packaging and thermal‑management solutions, including heatsinks, thermal interfaces, heat spreaders, conduction cooling, and airflow.
• Collaborate with RF, electrical, FPGA, software, systems, manufacturing, quality, supply chain, and test teams.
• Support the complete product lifecycle, including prototyping, fabrication, assembly, integration, environmental testing, qualification, production, and field support.
• Participate in design reviews and support configuration management, revision control, PLM, and engineering change processes.
• Investigate design, manufacturing, integration, and test issues and support root‑cause and corrective‑action activities.
• Work with suppliers and manufacturing teams to improve producibility, production readiness, cost, quality, and schedule performance.
• Own assigned technical tasks and, based on experience, lead technical efforts or mentor other engineers.
• Support occasional travel to customers, suppliers, test, or field locations.

Basic Qualifications (Required Skills & Experience)

• Bachelor’s degree in mechanical engineering or related discipline.
• Relevant experience in mechanical design, analysis, product development, or hardware integration.
• Level will be determined by qualifications and experience.
• Experience with 3D CAD software; SolidWorks preferred.
• Working knowledge of mechanical design, engineering drawings, materials, manufacturing processes, and GD&T.
• Familiarity with structural, thermal, vibration, or environmental analysis methods.
• Strong problem‑solving, communication, organizational, and technical documentation skills.
• Ability to work effectively in a collaborative, multidisciplinary environment.
• Must be a U.S. citizen and able to obtain and maintain a U.S. security clearance, if required.

Other Qualifications & Desired Competencies

• Experience with RF systems, radar, communications systems, phased arrays, electronic warfare, or embedded electronics.
• Experience with electronics packaging, high‑power RF hardware, or electromechanical systems.
• Experience using ANSYS or similar structural, thermal, CFD, or finite element analysis tools.
• Familiarity with thermal‑management technologies and environmental qualification testing.
• Knowledge of machining, sheet‑metal fabrication, additive manufacturing, composites, or other production processes.
• Experience with PLM, PDM, configuration management, production transition, supplier coordination, or manufacturing integration.
• Familiarity with AS9100, ISO 9001, or other regulated engineering environments.
• Experience leading technical tasks, conducting trade studies, or mentoring engineers.

Core Competencies

• Mechanical design and engineering analysis.
• Electronics packaging and thermal management.
• Design for manufacturability and assembly.
• Hands‑on hardware integration and testing.
• Cross‑functional collaboration and technical communication.
• Technical problem solving and root‑cause analysis.
• Configuration‑controlled documentation and task ownership.

Career Framework Track: Engineering Discipline: Mechanical Engineering Level: Based on qualifications and experience Focus Areas: Mechanical Design, Thermal Analysis, Structural Analysis, Electronics Packaging, Integration and Test, and Manufacturing Engineering

Location: This position is based in either Albuquerque, NM or Germantown, MD.

Salary Range $75,000 to $160,000 (This range is broad as we are hiring for multiple levels for this role. Salary will be determined within range based at entry, mid, or senior‑level based on level of experience.) The pay range for this job level is a general guideline only and not a guarantee of compensation or salary. Determination of official compensation or salary relies on several factors including, but not limited to, level of position, job responsibilities, geographic location, scope of relevant work experience, educational background, certifications, contract‑specific affordability, organizational requirements, alignment with local internal equity as well as alignment with market data.

Our compensation package also includes components designed to support employees’ total well‑being, which should be considered when evaluating our competitive benefits package. These benefits include health insurance, life insurance, disability, company holiday and paid time off, parental leave, 401(k) company match and contributions, professional development/training reimbursements, and other work/life programs.

Benefits

• health insurance
• life insurance
• disability
• company holiday and paid time off
• parental leave
• 401(k) company match and contributions
• professional development/training reimbursements
• other work/life programs

For more information about our company benefit offerings please visit: http://www.avinc.com/myavbenefits.

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.

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, or asylee. See 22 CFR § 120.15. Some positions will require current U.S. Citizenship due to contract requirements.

We also encourage you to review our company website at http://www.avinc.com to learn more about us.

Who We Are

Based in California, AeroVironment (AVAV) is a global leader in unmanned aircraft systems (UAS) and tactical missile systems. Founded in 1971 by celebrated physicist and engineer, Dr. Paul MacCready, we’ve been at the leading edge of technical innovation for more than 45 years. Be a part of the team that developed the world’s most widely used military drones and created the first submarine‑launched reconnaissance drone, and has seven innovative vehicles that are part of the Smithsonian Institution’s permanent collection in Washington, DC. Join us today in developing the next generation of small UAS and tactical missile systems that will deliver more actionable intelligence to our customers so they can proceed with certainty - and succeed.

What We Do

Building on a history of technological innovation, AeroVironment designs, develops, produces, and supports an advanced portfolio of unmanned aircraft systems (UAS) and tactical missile systems. Agencies of the U.S. Department of Defense and allied military services use the company’s hand‑launched UAS to provide situational awareness to tactical operating units through real‑time, airborne reconnaissance, surveillance, and target acquisition. We are proud to be an EEO/AA Equal Opportunity Employer, including disability/veterans.

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 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.