Principal Mechanical Engineer

AV; Huntsville (AL); On-site; USD 147,000 - 224,000; Full time

Benefits offered by this job

9/80 work schedule

Medical, dental, vision

401K with company matching

Paid holidays

Job summary

AV in Huntsville, Alabama is seeking a Principal Mechanical Engineer to lead the mechanical design, testing and packaging of high-altitude aerospace electronics. The role involves overseeing production of electrical machines, developing packaging, and guiding subcontractor development efforts.

Requirements include a Bachelor's in Mechanical Engineering, 12–15 years' experience with 7+ years in aerospace/industrial production, proficiency in SolidWorks and ANSYS, and familiarity with

Qualifications

• Bachelor's degree in Mechanical Engineering is required or equivalent combination of education, training, and experience.
• 12–15 years of relevant mechanical engineering experience, with 7+ years in production rotating electrical machines or electronics packaging for aerospace.
• Experience specifying mechanical subsystems per MIL-STD 961D or equivalent.
• Proficient with SolidWorks and ANSYS for modeling and analysis; ANSYS Icepack for thermal analysis.

Responsibilities

• Lead mechanical design, testing, and production of electrical machines and electronics packaging for aerospace.
• Manage mechanical analysis, thermal management, and material selection for high-altitude environments.
• Develop mechanical drawings and BOMs; create assembly instructions and test procedures.
• supervise teams on complex assignments and coordinate subcontractor work as needed.
• Ensure compliance with MIL-STD-961D and related standards during subsystem development.

Skills

Mechanical design

Finite element analysis

Thermal management

Materials selection

Leadership

Project management

CAD drafting

System integration

Education

Bachelor's degree in Mechanical Engineering

MS in Mechanical Engineering preferred

ASME senior membership preferred

Tools

SolidWorks

ANSYS

ANSYS Icepack

Job description

Worker Type

Regular

Summary

The Principal Mechanical Engineer applies engineering techniques to design, install, modify, analyze, repair and test tools, engines, machines and other mechanically functioning equipment. In this role, The Sr. Staff Mechanical Engineer leads in the mechanical design, testing, and production of electrical machines as well as the design of electronics packaging for high altitude aerospace applications. One leads the mechanical packaging development effort for electronic equipment that withstand stringent environmental requirements (i.e., mass, volume, thermal, vibration). Manages mid-size development projects outsourced to sub-contractors (development of a system, equipment or components).

Position Responsibilities

• Leads or supports the thermal, structural, dynamic, and fluid flow analysis efforts for electronics equipment
• Leads the testing and data collection in the laboratory and the field
• Models the mechanical devices and selects the proper material
• Performs stress and fatigue analysis; Performs thermal analysis and selects bonding material
• Develops mechanical drawings and specifies the dimensional tolerances
• Develops and implements assembly instructions and test procedures
• Develops and implements test plans and test procedures to verify designs
• Works on significant and unique issues where analysis of situations or data requires an evaluation of intangibles. Exercises independent judgment in methods, techniques and evaluation criteria for obtaining results
• Acts independently to determine methods and procedures on new or special assignments. May supervise the activities of others.
• Other duties as assigned

Basic Qualifications (Required Skills & Experience)

• Bachelor's degree in Mechanical Engineering is required or equivalent combination of education, training, and experience
• Minimum 12 – 15 years of relevant technical experience in Mechanical Engineering, of which a minimum of 7 years in developing for production rotating electrical machines, electronics equipment packaging solution, and/or mechanical devices solutions for industrial and aerospace applications
• Experience developing requirements specification for mechanical subsystems and according to MIL-STD 961D standard or equivalent
• Has sufficient proficiency with the following CAD /CAE tools to perform one's position responsibilities:
• SolidWorks for mechanical modeling.
• ANSYS for structural and fatigue analysis
• ANSYS Icepack for thermal analysis.
• Extensive experience with Solid Works
• Extensive experience with designing electrical rotating machines for high-performance applications
• Extensive experience with thermal management tradeoffs and solutions as well as materials properties
• Experienced with bonding techniques for extreme environmental conditions using different adhesives
• Experienced with manufacturing methodologies of electrical machines and with creating and maintaining product document tree
• Experience with creating and maintaining products bill of materials (BOM)
• Experience with test and measurement techniques, such as torque transducer calibration and instrumentation.

Other Qualifications & Desired Competencies

• MS in Mechanical Engineering is preferred
• Recognition by a reputable international engineering society such as ASME at the senior membership level or higher is preferred
• Demonstrated familiarity with MIL-STD-810 or DO-160 and familiarity with MIL-STD 961D standards (or equivalent) for developing subsystem technical specifications
• Demonstrated full understanding & knowledge of engineering principles in the technical discipline. Demonstrates ability to work 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)

Special Requirements

• U.S. Citizenship required. Presently holds or capable of obtaining a U.S. Security Clearance
• Occasionally may be required to travel within the Continental U.S.

Clearance Level

No Clearance

The Salary Range For This Role Is

$147,000 - $224,250

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 included seven platforms in the Smithsonian—but we’re not building history, we’re building what’s next.

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. Citizenship required