Mechanical Engineering DE Analysis, Mid-level to Senior

About the role

Worker Type

Regular

Position Summary

AeroVironment is seeking a Mechanical Engineer with a strong background in engineering analysis to support the development of advanced directed energy systems. This role will focus on the analysis, design, integration, and qualification of complex mechanical and electromechanical hardware used in high-performance defense applications.

The ideal candidate will have experience applying structural, thermal, dynamic, and mechanical engineering principles to systems operating in demanding environments. The engineer will work closely with systems, electrical, optical, controls, manufacturing, and test teams to develop robust designs from concept through production.

This position may be filled at the mid-level or senior level, depending on the candidate's experience, technical depth, and demonstrated leadership.

Responsibilities

Perform mechanical engineering analysis supporting the design and development of directed energy systems and subsystems.

Develop, review, and validate analytical models for

• Static and dynamic structural performance
• Vibration, shock, and acoustic environments
• Modal response and resonance
• Thermal management and heat transfer
• Thermomechanical behavior
• Fatigue, fracture, and durability
• Loads, stiffness, and structural margins
• Mechanisms, joints, mounts, and precision alignment features

• Use finite element analysis and other engineering tools to evaluate component and system performance.
• Define analysis assumptions, boundary conditions, material properties, load cases, and acceptance criteria.
• Correlate analytical predictions with test data and update models based on observed hardware performance.
• Conduct trade studies to optimize designs for weight, strength, stiffness, thermal performance, manufacturability, cost, and reliability.
• Support the development of mechanical architectures, components, assemblies, and subsystem designs.
• Create and review CAD models, engineering drawings, analysis reports, specifications, and technical presentations.
• Collaborate with design engineers to translate analysis results into practical design improvements.
• Participate in design reviews, requirements development, configuration management, and technical peer reviews.
• Analyze test results, investigate failures or anomalies, and perform root-cause assessments.
• Support prototype fabrication, hardware integration, qualification testing, and transition to production.
• Work with manufacturing, quality, suppliers, and test organizations to resolve technical issues.
• Communicate technical findings and recommendations to engineering leadership and program stakeholders.
• At the senior level, provide technical leadership, mentor engineers, and lead analysis activities for major subsystems or projects.

Required Qualifications

• Bachelor's degree in Mechanical Engineering, Aerospace Engineering, or a related technical discipline.
• US citizenship required due to the Government program we support
• Mid-Level: Typically 3 or more years of relevant mechanical engineering and analysis experience.
• Senior-Level: Typically 7 or more years of relevant experience, including ownership of complex analysis tasks or technical leadership.
• Demonstrated experience with mechanical engineering analysis for complex aerospace, defense, or industrial systems.
• Experience with finite element analysis and structural/thermal mechanics.
• Working knowledge of thermal analysis, vibration, shock, dynamics, and material behavior.
• Experience developing engineering models and documenting analytical methods, assumptions, results, and conclusions.
• Experience correlating analytical predictions with test results or hardware performance.
• Familiarity with mechanical design principles, GD&T, tolerance analysis, materials, and manufacturing processes.
• Experience with SolidWorks and engineering documentation practices.
• Ability to work effectively in a multidisciplinary team environment.
• Strong written, verbal, and technical communication skills.
• Ability to obtain and maintain a U.S. security clearance, if required.
• Ability to comply with applicable export-control regulations, including ITAR requirements.

Preferred Qualifications

• Experience with directed energy systems, high-power laser systems, electro-optical systems, precision pointing systems, or stabilized platforms.
• Experience with structural and thermal analysis of high-power electronics, lasers, optical systems, or energy-storage systems.

• Experience using tools such as: ANSYS
• Abaqus
• NASTRAN / Patran
• MATLAB

• Experience with coupled thermal-structural, nonlinear, transient, or dynamic analysis.
• Experience with fatigue, fracture mechanics, damage tolerance, or reliability analysis.
• Experience analyzing airborne, ground, maritime, or other ruggedized defense systems.
• Familiarity with environmental qualification testing and applicable aerospace or military standards.
• Experience with precision mechanisms, gimbals, optical benches, vibration isolation, or alignment-critical assemblies.
• Experience leading analysis reviews, technical investigations, or multidisciplinary development efforts.
• Experience mentoring junior engineers and coordinating work across technical teams.

Key Competencies

• Strong fundamentals in mechanics, materials, heat transfer, dynamics, and structural analysis.
• Ability to assess the validity and limitations of analytical models.
• Sound engineering judgment and a methodical approach to problem-solving.
• Ability to convert analysis results into clear, actionable design recommendations.
• Strong attention to detail and technical documentation skills.
• Ability to balance analytical rigor with program cost and schedule objectives.
• Effective collaboration across mechanical, electrical, optical, systems, manufacturing, and test disciplines.
• Ability to work independently on challenging technical problems.
• Commitment to product quality, mission success, and continuous improvement.
• Level Expectations

Mid-Level Mechanical Engineer

• Independently performs assigned structural, thermal, or mechanical analyses.
• Develops models, evaluates results, and documents technical conclusions.
• Supports design decisions, testing, integration, and troubleshooting.
• Works with senior engineers to resolve complex technical issues.
• Develops increasing ownership of subsystem-level analysis activities.

Senior Mechanical Engineer

• Leads analysis efforts for complex components, subsystems, or systems.
• Establishes analysis approaches, methods, requirements, and technical direction.
• Reviews and approves models, results, assumptions, and analysis reports.
• Drives correlation between analysis and test and leads resolution of discrepancies.
• Provides technical leadership during design reviews and qualification activities.
• Mentors junior engineers and coordinates analysis activities across disciplines.
• Contributes to program planning, risk management, proposals, and technical strategy.

Education and Experience Leveling

The final position level, scope, and compensation will be determined based on the candidate's education, relevant experience, technical expertise, leadership capability, and program needs.

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 will be asked to provide specific documentation to verify U.S. person status under the ITAR and the EAR.

• A "U.S. person" according to their 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, 401(k) with company matching, and flexible work schedule options. Depending on your business unit, role, and customer contract requirements, select programs may offer a 9/80 work schedule and paid holiday shutdown.

Principals only need apply. NO agencies please.

What We Do

Building on a history of technological innovation, AeroVironment designs, develops, produces, and supports an advanced portfolio of unmanned aircraft systems (UAS) and tactical missile systems. Agencies of the U.S. Department of Defense and allied military services use the company's hand-launched UAS to provide situational awareness to tactical operating units through real-time, airborne reconnaissance, surveillance, and target acquisition.

ITAR