Principal Energetics Engineer

BlueHalo; Huntsville (AL); On-site; USD 134,000 - 204,000; Full time

Benefits offered by this job

Medical, dental, vision

401K with company matching

9/80 work schedule

Paid holiday shutdown

Job summary

AeroVironment, Inc. in Huntsville, AL is seeking a Principal Mechanical Energetics Engineer to lead SRM/Warhead supplier programs and drive complex energetics analyses.

You will oversee specifications, testing, and integration with systems engineering to meet stringent environmental and performance requirements. The role emphasizes leadership, MBSE collaboration, and hands-on development of mechanical packaging for defense and commercial missile systems.

Qualifications

• Minimum 8–12 years of SRM/warhead development experience.
• Experience with mechanical subsystems requirements specifications.
• Proficient in BOM creation and product data management.
• Knowledge of MIL-STD-810/DO-160 and MIL-STD 961D is a plus.
• Strong analytical and problem-solving abilities; good communication.

Responsibilities

• Lead development of SRM and Warhead supplier programs.
• Interface with suppliers, AV, and customers on energetics.
• Conduct thermal, structural, dynamic and fluid analyses.
• Lead testing and data collection in lab and field environments.
• Develop specifications, drawings, tolerances, and assembly docs.
• Mentor high-performing engineering teams.

Skills

CREO CAD modeling

ANSYS structural fatigue

ANSYS Icepack thermal

Mechanical subassemblies

BOM management

Test & measurement techniques

Education

Bachelor's degree in mechanical engineering

MS/MS in Mechanical Engineering

PhD in a relevant field

Tools

CREO

ANSYS

ANSYS Icepack

Job description

Worker Type

Regular

Job Description

The Principal Mechanical Energetics Engineer is considered a subject matter expert in the discipline. One demonstrates visionary & professional concepts in developing resolution to critical issues and broad design matters pertaining to the development of a variety of innovative missile systems for defense and commercial applications. The Principal Mechanical Energetics Engineer will function as the primary point of contact for the supplier efforts to design/build/test/deliver Solid Rocket Motors (SRM) and Warheads for complex a missile system. This individual will lead/support the integration and requirements definitions for these subsystems to include generation of specifications and working with systems engineering to complete MBSE activities. Further skills will include driving mechanical packaging of these items to withstand stringent environmental requirements (i.e., mass, volume, thermal, vibration).

Position Responsibilities

• Personifies the AV pillar of “Innovation”.
• Lead development efforts of SRM and Warhead suppliers
• Leads proposal development for energetics related to new missile programs
• Functions as the interface between suppliers, AV, and the customer as it relates to energetics efforts
• Leads or supports the thermal, structural, dynamic, and fluid flow analysis efforts
• Leads the testing and data collection in the laboratory and the field
• Performs stress and fatigue analysis; Performs thermal analysis and selects bonding material
• Develops specifications, mechanical drawings, and specifies the dimensional tolerances
• Develops assembly instructions and test procedures
• Develops/supports test plans and test procedures to verify designs
• Works on complex issues where analysis of situations or data requires an in-depth knowledge of variable factors
• Develops and mentors high-performing engineering teams
• Other duties as assigned

Basic Qualifications (Required Skills & Experience)

• A Minimum of 12 years and a Bachelor's degree; 8 years and a Master's degree; or 5 years and a PhD of relevant technical experience in SRM and Warhead development
• Experienced in developing requirements specification for mechanical subsystems
• Has sufficient proficiency with the following CAD/CAE tools to perform one's position responsibilities:
• CREO for mechanical modeling.
• ANSYS for structural and fatigue analysis
• ANSYS Icepack for thermal analysis.
• Experienced with manufacturing methodologies of electrical/mechanical assemblies
• Experienced with creating and maintaining products bill of materials (BOM)
• Experienced with test and measurement techniques, such as torque transducer calibration and instrumentation

Other Qualifications & Desired Competencies

• MS degree in Mechanical Engineering is preferred
• Demonstrates familiarity with MIL-STD-810 or DO-160
• Demonstrates familiarity with MIL-STD 961D standards (or equivalent) for developing subsystem technical specifications
• Demonstrates full understanding & knowledge of engineering principles in the technical discipline and successfully works independently
• Effectively articulates concepts and ideas to both technical and non-technical staff
• Able to excel in a fast-paced, deadline-driven environment, where small teams share a broad variety of duties
• Displays strong initiative and drive to accomplish goals and meet company objectives
• Takes ownership and responsibility for current and past work products
• Is committed to learning from mistakes and driven to improve and enhance performance of oneself, others, and the company
• Has effective problem-solving, analytical, interpersonal and communication skills (Verbal and written)
• Focuses on teamwork, collaboration and puts the success of the team above one's own interests

Physical Demands

• Ability to work in an office and production environment (Constant)
• Required to sit and stand for long periods; talk, hear, and use hands and fingers to operate a computer and telephone keyboard (Frequent)
• Performs stress and fatigue analysis; Performs thermal analysis and selects bonding material
• Develops specifications, mechanical drawings, and specifies the dimensional tolerances
• Develops assembly instructions and test procedures
• Develops/supports test plans and test procedures to verify designsWorks on complex issues where analysis of situations or data requires an in-depth knowledge of variable factors
• Executes team assignments effectively following the given schedule, milestone, and available resources. May coordinate activities of other personnel (Team Lead).
• Other duties as assigned

Basic Qualifications (Required Skills & Experience)

• Minimum 8 - 12 years of relevant technical experience in SRM and Warhead development
• Experienced in developing requirements specification for mechanical subsystems
• Has sufficient proficiency with the following CAD /CAE tools to perform one's position responsibilities:
• CREO for mechanical modeling.
• ANSYS for structural and fatigue analysis
• ANSYS Icepack for thermal analysis.
• Experienced with manufacturing methodologies of electrical/mechanical assemblies
• Experienced with creating and maintaining product document tree
• Experienced with creating and maintaining products bill of materials (BOM)
• Experienced with test and measurement techniques, such as torque transducer calibration and instrumentation

Other Qualifications & Desired Competencies

• MS degree in Mechanical Engineering is preferred
• Demonstrates familiarity with MIL-STD-810 or DO-160
• Demonstrates familiarity with MIL-STD 961D standards (or equivalent) for developing subsystem technical specifications
• Demonstrates full understanding & knowledge of engineering principles in the technical discipline and successfully works independently
• Effectively articulates concepts and ideas to both technical and non-technical staff
• Able to excel in a fast-paced, deadline-driven environment, where small teams share a broad variety of duties
• Displays strong initiative and drive to accomplish goals and meet company objectives
• Takes ownership and responsibility for current and past work products
• Is committed to learning from mistakes and driven to improve and enhance performance of oneself, others, and the company
• Has effective problem-solving, analytical, interpersonal and communication skills (Verbal and written)
• Focuses on teamwork, collaboration and puts the success of the team above one's own interests

Physical Demands

• Ability to work in an office and production environment (Constant)
• Required to sit and stand for long periods; talk, hear, and use hands and fingers to operate a computer and telephone keyboard (Frequent)

Clearance Level

Secret

Salary Range

The salary range for this role is: $133,500 - $203,750

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 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.

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.

ITAR

U.S. Citizenship is required. Secret or Top Secret clearance, or the ability obtain a clearance is desired.