Mechanical Engineering Intern

BlueHalo; Petaluma (CA); On-site; USD 28,000 - 41,000; Full time

Benefits offered by this job

Relocation assistance

Housing stipend

Job summary

AeroVironment’s Summer Internship Program offers a hands-on Mechanical Engineering Intern role onsite at the Petaluma, CA office. You’ll work on the UAS product line, designing mechanical components, creating 3D CAD models in SolidWorks, and supporting simulation and testing activities.

strong collaboration with engineers and opportunities to contribute to real projects. Applicants should be enrolled in college or be recent graduates with a minimum 3.0 GPA and a willingness to relocate if needed

Qualifications

• Pursuing a Bachelor’s degree in Mechanical or Aerospace Engineering or related field.
• Basic experience with 3D CAD software (preferably SolidWorks).
• Exposure to hands-on prototyping, lab testing, or mechanical assembly through academic or personal projects.

Responsibilities

• Assist in the design of mechanical components and systems including airframes and launch systems.
• Create and modify 3D CAD models and assemblies using SolidWorks.
• Support simulations using SolidWorks Simulation or ANSYS and participate in prototyping activities.
• Generate technical drawings and BOMs per industry drafting standards.
• Collaborate with engineers on design reviews and testing activities.

Skills

3D CAD

SolidWorks

Hands-on prototyping

Communication

Eagerness to learn

Education

Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, or related field

Tools

SolidWorks

SolidWorks Simulation

ANSYS

Job description

Worker Type

Supplemental

Job Description

Summer Internship Program

Our paid Summer Internship Program is designed to provide students with an immersive, hands‑on experience within the aerospace and defense industry. Interns work alongside AV team members on meaningful projects involving cutting‑edge technology while developing professional relationships, strategic problem‑solving skills, and practical experience in a full‑time work environment.

This is a 12-week, onsite program intended for highly motivated and passionate students who are currently enrolled in college or are recent graduates. Applicants must have a minimum 3.0 GPA, with a preference for students at the junior level or above.

Our program has been recognized by Yello and WayUp as one of the Top 100 Internship Programs in the United States for multiple years.

Depending on the team and location, students who are willing to relocate for their internship may be eligible for a relocation and housing reimbursement stipend.

This position will report onsite to the Petaluma, CA office and work on our UAS product line.

Mechanical Engineering Intern

Position Responsibilities

• Assist in the design of mechanical components and systems, including airframes, payload enclosures, ground equipment, launch systems, and electro‑mechanical assemblies
• Create and modify 3D CAD models and assemblies using SolidWorks
• Support simulation and analysis tasks using tools like SolidWorks Simulation or ANSYS
• Participate in prototype fabrication, assembly, and testing using in‑house tools and rapid prototyping methods (e.g., 3D printing)
• Help generate technical drawings and bills of materials in accordance with industry drafting standards
• Collaborate with engineers to support design reviews, testing activities, and integration of mechanical systems
• Contribute to documentation and reporting of design progress and test results
• Learn and assist in configuration control and engineering change processes
• Perform other tasks as assigned to support ongoing development efforts

Basic Qualifications (Required Skills & Experience)

• Currently pursuing a Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, or a related field
• Basic experience with 3D CAD software (preferably SolidWorks)
• Familiarity with mechanical components such as machined parts, sheet metal, plastic parts, or composite materials
• Exposure to hands‑on prototyping, lab testing, or mechanical assembly through academic or personal projects
• Strong communication and organizational skills
• Eagerness to learn and contribute in a fast‑paced, collaborative environment

Preferred Qualifications & Competencies

• Familiarity with SolidWorks EPDM or other Product Data Management (PDM) systems
• Exposure to ASME Y14.5 GD&T standards and engineering drawing practices
• Interest or experience in designing test fixtures or tooling
• Basic understanding of structural dynamics or thermodynamics in mechanical design
• Demonstrated problem‑solving ability and attention to detail
• Self‑motivated, proactive, and eager to take initiative
• Team player who values collaboration and continuous improvement

Physical Demands

• Ability to work in an office and light R&D lab environment (Constant)
• Required to sit or stand for extended periods; use hands and fingers to operate a computer or tools (Frequent)

Clearance Level

No Clearance

The salary range for this role is:

AeroVironment considers several factors when extending an offer, including but not limited to, the location, the role and associated responsibilities, a candidate’s 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 (“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. For more information about our company benefit offerings please visit: http://www.avinc.com/myavbenefits.

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

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.

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. Citizen, U.S. Permanent Resident (Green Card holder), asylee/refugee status as defined by 8 U.S.C. 1324b(a)(3) or a person approved for an export license from the appropriate governing agency.