Directed Energy Senior Manufacturing and Process Engineer

Worker Type Regular Job Description Summary The Directed Energy Senior Manufacturing and Process Engineer is responsible for developing, implementing, optimizing, and sustaining manufacturing processes for complex products and assemblies. This role serves as a technical manufacturing engineering organization, working cross-functionally with Design Engineering, Quality, Supply Chain, Operations, and Test Engineering to improve productivity, quality, cost, safety, and delivery performance. The Senior Manufacturing and Process Engineer will lead process-development and continuous-improvement projects, support Research & Development, New Product Development and Introduction, resolve difficult production issues, and provide technical mentorship to less experienced engineers and manufacturing personnel. Position Responsibilities Develop, document, validate, and improve manufacturing processes for complex products, assemblies, and test systems. Support manufacturing and process engineering activities for new product introduction, design transfers, and production transitions. Review product designs for manufacturability, assembly, inspection, serviceability, and cost effectiveness. Create and maintain manufacturing documentation, including: Work instructions Manufacturing process specifications Standard operating procedures Process flow diagrams Assembly aids and tooling requirements Bills of material and routing information Design and implement process improvements using Lean Manufacturing, Six Sigma, root-cause analysis, and other continuous-improvement methodologies. Support investigations into production problems, nonconformances, yield losses, and process escapes. Help develop corrective and preventive actions and verify their effectiveness. Establish process parameters, acceptance criteria, inspection methods, and production controls. Design or coordinate the development of fixtures, tooling, gauges, test equipment, and other production aids. Support equipment selection, installation, qualification, and maintenance planning. Analyze production data to identify trends, constraints, waste, and opportunities for improvement. Support process validation activities, including capability studies, first article inspections, qualification testing, and production readiness reviews. Partner with Quality Engineering to support root-cause analysis, material review board activities, and corrective-action investigations. Support supplier development, component qualification, and outsourced manufacturing processes as needed. Provide technical guidance and mentorship to Manufacturing/Process Engineers I and II and production personnel. Participate in design reviews, production readiness reviews, risk assessments, and program reviews. Ensure processes comply with applicable engineering, quality, safety, environmental, and regulatory requirements. Support production operations and troubleshoot urgent manufacturing issues. Perform other duties as assigned. Basic Qualifications (Required Skills & Competencies) Bachelor’s degree in Manufacturing Engineering, Mechanical Engineering, Industrial Engineering, Electrical Engineering, or a related technical field. Typically, 5-8 years of relevant manufacturing or process engineering experience, or an equivalent combination of education and experience. Demonstrated experience developing and sustaining manufacturing processes for complex products or assemblies. Experience with new product introduction, production transition, and design-for-manufacturability activities. Proven ability to support cross-functional technical projects. Strong knowledge of root-cause analysis, corrective action, process capability, and continuous-improvement methods. Experience creating and maintaining manufacturing documentation in a controlled environment. Ability to read and interpret engineering drawings, specifications, bills of material, and related technical documentation. Strong analytical, problem-solving, communication, and organizational skills. Ability to work effectively with engineering, operations, quality, supply chain, and external suppliers. Proficiency with Microsoft Office or equivalent productivity tools. U.S. Citizenship is required Ability to obtain and maintain a DoD security clearance Other Qualifications & Desired Competencies Experience with ERP, MRP, MES, PLM, or manufacturing document-control systems. Experience with CAD tools and the design of fixtures, tooling, or production aids. Experience with automation, robotics, test equipment, or manufacturing systems integration. Experience working in aerospace, defense, aviation, medical device, electronics, or another highly regulated manufacturing environment. Familiarity with AS9100, ISO 9001, IPC, or other applicable quality standards. Experience supporting electromechanical, precision-machined, or highly integrated products. Core Competencies Manufacturing process development Design for manufacturability and assembly Structured problem solving Continuous improvement Data analysis and decision-making Cross-functional collaboration Clear technical communication Mentoring and knowledge transfer Attention to detail and quality ownership Physical Demands and Work Environment Ability to work in an office, engineering laboratory, and manufacturing environment. Ability to wear required personal protective equipment. Ability to occasionally lift, carry, or manipulate materials and equipment within applicable safety limits. Ability to stand, walk, bend, reach, and work around production equipment as required. Ability to support occasional off-shift or extended-hours production activities. Travel may be required based on business needs. Clearance Level No Clearance The salary range for this role is: $91,000 - $138,750 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: . We also encourage you to review our company website at 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 required. Must be willing to work on government contracts and have the ability to obtain a security clearance.