Research Engineer- Adaptive Structures

AeroVironment, Inc.; Upper Valley Trailer Court (OH); On-site; USD 75,000 - 114,000; Full time

Benefits offered by this job

Medical benefits

Dental benefits

Vision benefits

401K with company matching

9/80 schedule

Holiday shutdown

Job summary

AeroVironment, Inc. is seeking an entry-level Research Engineer in Adaptive Structures to join the Dayton, OH team onsite at Wright-Patterson AFB. You will design, prototype, and rigorously test deployable structures, bridging theory and physical implementation.

The role emphasizes hands-on R&D, collaboration with Air Force Research Laboratory, and development of next-generation deployable mechanisms with real-world performance goals.

Qualifications

• Advanced degree in a related technical discipline is preferred (MS/PhD).
• U.S. Citizenship is required to access government facilities.
• Experience with additive manufacturing, composite layup techniques, and computational modeling is desired.

Responsibilities

• Design and prototype functional physical models from concepts.
• Support experimental test campaigns to evaluate deployment dynamics.
• Evaluate packaging efficiency and strength-to-weight performance with advanced materials.
• Instrument prototypes with motion capture and strain sensors; analyze data to validate models.

Skills

Python

Matlab

Julia

Education

Advanced degree in Aerospace Engineering

Mechanical Engineering

Physics

Applied Mathematics

Job description

Worker Type Regular Job Description Research Engineer- Adaptive Structures Summary AV, Inc. is seeking an entry level Research Engineer in Adaptive Structures to work at Wright-Patterson Air Force Base in Dayton, OH. The position will be performed in collaboration with the Foundational Technologies Directorate of the Air Force Research Laboratory. We are seeking an innovative and hands‑on R&D Engineer to join our Adaptive Structures team. In this role, you will design, prototype, and rigorously test next‑generation deployable structures. From origami‑inspired RF reflectors and solar arrays to self‑erecting shelters, you will bridge the gap between theoretical kinematics and physical reality, creating mechanisms that pack small and perform big.

Position Responsibilities

• Design & Prototype: Translate conceptual kinematic and folding patterns into functional physical models using rapid iteration.
• Experimental Testing: Support the development and execution of experimental test campaigns to evaluate deployment dynamics, stiction, repeatability, and structural integrity under simulated environmental conditions.
• Material Integration: Work with advanced composites, additive manufacturing materials and flexible thin-film membranes to evaluate and improve packaging efficiency and strength-to-weight performance.
• Data Analysis & Communication: Instrument prototypes with motion capture and strain sensors, analyzing dynamic deployment behavior to validate and refine finite element models.

Position Qualifications

• This position involves working within a government facility and requires U.S. Citizenship
• An advanced degree in Aerospace Engineering, Mechanical Engineering, Physics, Applied Mathematics, or other related technical discipline is desired (recent Ph.D. or MS is preferred; graduate students with a defense scheduled will also be considered).
• Working knowledge or academic/research experience in one or more of the following areas: additive manufacturing, composite layup techniques, and computational modeling
• Prior experience with technical computing languages such as Python, Matlab, and/or Julia
• Excellent oral and written communication skills are a prerequisite for employment.

Location

Onsite in Dayton, OH

Preferred Qualifications & Desired Competencies

• Expertise in additive manufacturing, composite layup techniques, and computational modeling
• Experience with adaptive structures
• Experience with prototype formation

Physical Demands

Travel required to domestic US sites - up to 10%. Ability to work in an office and lab environment.

Clearance Level

No Clearance

The salary range for this role is:

$74,500 - $113,500

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") and the Department of Defense Export Control Program (DODEC). 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. ITAR U.S. Citizenship required

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.

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.

EEO / Diversity Statement

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.

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