Principal Mechanical Engineer

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

Benefits offered by this job

Medical, dental, vision

401K with company matching

9/80 work schedule

Paid holiday shutdown

Job summary

AeroVironment is seeking a Principal/Sr. Staff Mechanical Engineer to lead mechanical design, testing, and packaging for high-altitude aerospace electronics. You will guide development, perform analyses, and manage subcontractor activities for complex systems.

The role emphasizes independent judgment, experience with production rotating machines, and ability to work in a fast-paced environment. U.S. citizenship and potential travel are required.

Qualifications

• Bachelor's degree in Mechanical Engineering or equivalent required.

Responsibilities

• Leads or supports the thermal, structural, dynamic, and fluid flow analysis efforts for electronics equipment.
• Leads testing and data collection in laboratory and field.
• Develops mechanical drawings and specifies dimensional tolerances.
• Develops and implements test plans and procedures to verify designs.

Skills

Independent problem solving

Communication

Team leadership

Education

Bachelor's degree in Mechanical Engineering

MS in Mechanical Engineering preferred

Tools

SolidWorks

ANSYS

ANSYS Icepack

Job description

Worker Type

Regular

Job Description

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 broader 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

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.

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.

U.S. Citizenship required