Principal Mechanical Engineer

Role details

Worker Type Regular Job Description The Principal Mechanical Engineer applies advanced engineering techniques to design, install, modify, analyze, repair, and test air vehicles, propulsion systems, support equipment, and related subsystems. In this role, the Principal Mechanical Engineer leads the mechanical design, testing, and production of unmanned systems and munitions, including advanced polymer matrix composite structures (such as carbon fiber/epoxy systems) and high-performance electronics packaging for aerospace applications.

You will lead the mechanical packaging and structural development effort for structural components that withstand stringent environmental requirements (i.e., mass, volume, thermal, vibration, and dynamic loading) while managing mid-size development projects and acting as a technical authority. Position Responsibilities Architect Composite & Mechanical Systems: Lead the structural design, tailoring, and optimization of advanced carbon fiber composite components, matching ply orientations to complex bending, axial, and torsional load paths.

Lead Multi-Disciplinary Analysis: Spearhead thermal, structural, dynamic, and fluid flow analysis efforts for airframe structures using advanced modeling and analysis tools. Manage Laboratory & Field Testing: Lead testing, data collection, and physical qualification testing in the laboratory and the field to verify structural and environmental designs. Material & Process Selection: Model mechanical devices, select proper materials, perform stress/fatigue/thermal analysis, and specify bonding materials and techniques for extreme environmental conditions.

Tooling & Manufacturing Integration: Oversee composite manufacturing methods (autoclave prepreg curing, RTM, OOA), tooling development, thermal residual stress management, and galvanic corrosion mitigation between carbon fibers and reactive metals. Documentation & Compliance: Develop mechanical drawings, geometric dimensioning and tolerancing (GD&T), product document trees, Bills of Materials (BOMs), assembly instructions, and rigorous test plans/procedures. Technical Leadership: Act independently to determine methods and procedures on new or special assignments.

Act as the primary technical focal point for composite architecture, guiding cross-functional teams and mentoring senior/staff-level engineers. Project Oversight: Manage mid-size development projects outsourced to sub-contractors (development of systems, equipment, or components). Perform other duties as assigned.

Basic Qualifications

(Required Skills & Experience) Education: B.S. in Mechanical Engineering, Aerospace Engineering, or Materials Science (M.S. or Ph.D. preferred).

Experience

Minimum 12 to 15 years of relevant technical experience in Mechanical Engineering, with at least 6 to 7 years specifically focused on the structural design, analysis, and manufacturing of advanced polymer matrix composites (e.g., carbon fiber/epoxy systems) for aerospace applications. Analytical Mastery: Proven expertise in finite element analysis (FEA) of orthotropic and isotropic materials using tools like ANSYS (including ANSYS Icepack for thermal analysis), Abaqus, or NASTRAN, specifically handling failure criteria (e.g., Tsai-Wu, Hashin) and progressive damage modeling.

Tooling & Processing: Deep familiarity with composite manufacturing methods—such as autoclave prepreg curing, resin transfer molding (RTM), or out-of-autoclave (OOA) processing—and their direct impacts on structural performance. Technical Standards & Requirements: Experience developing requirements specifications for mechanical subsystems according to MIL-STD 961D standard or equivalent. Tooling & Software Proficiency: Extensive experience with SolidWorks for mechanical modeling and design, as well as test and measurement techniques (e.g., torque transducer calibration and instrumentation). Must be a U.S.

Citizen eligible to obtain and maintain a Security Clearance Other Qualifications & Desired Competencies Design & PLM Software: Advanced proficiency in 3D CAD platforms and specialized composite ply-modeling modules (e.g., FiberSIM). Full Lifecycle Track Record: Demonstrated history of taking complex composite structures and electronic packaging from conceptual trade studies through Critical Design Review (CDR), tooling sign-off, and physical qualification testing.

Multidisciplinary Integration: Working knowledge of secondary operations, including precision machining of carbon fiber reinforced polymers (CFRP), galvanic corrosion mitigation strategies, and hybrid metallic-composite joint design. Industry & Quality Standards: Familiarity with relevant regulatory, quality, or military/aerospace specifications (e.g., MIL-STD-810, DO-160, FAA, DOD, ASTM test standards, or AS9100 quality frameworks). Recognition by a reputable international engineering society (such as ASME at the senior membership level or higher) is preferred.

Leadership & DFM Mindset: Strong adherence to Design for Manufacturability (DFM), balancing aggressive mass-reduction targets with realistic shop-floor non-recurring engineering (NRE) and tooling costs. Proven ability to articulate concepts, mentor staff, and foster teamwork. 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. 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. Principals only need apply. NO agencies please. 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. ITAR U.S. Citizenship is required. Secret or Top Secret clearance, or the ability obtain a clearance is desired.