Senior- Scaled Inorganic Particle Synthesis Scientist

Worker Type Regular Job Description About AeroVironment AeroVironment (AV) is a global leader in autonomous, multi-domain robotic systems, tactical missile systems, and high-altitude pseudo-satellites. Founded on a legacy of groundbreaking aerospace innovation, AV redefines mission-critical capabilities across air, land, sea, space, and cyber domains. Position Overview AeroVironment is seeking a Scaled Inorganic Particle Synthesis Scientist to drive advanced materials development for high-performance defense systems. In this role, you will lead the bridge between benchtop chemical discovery and batch/continuous scale-up of novel inorganic powders, ceramic precursors, and high-temperature functional nanoparticles. As a Senior scientist, you will act as a key subject matter expert (SME), operating with high autonomy while providing technical mentorship to lower-tier scientists and engineers. You will lead cross-functional projects, manage lab-to-pilot scale-up workflows, and collaborate closely with government research partners (e.g., Air Force Research Laboratory - AFRL) and internal flight/warhead structural teams. Key Responsibilities Lead technical execution for the synthesis, purification, and pilot-scale batch production of advanced inorganic powders, non-oxide ceramics, and high-temperature precursors. Develop scalable wet-chemical, sol-gel, vapor-phase, or solid-state synthetic routes to transition novel formulations from gram-scale research to multi-kilogram production. Serve as the technical lead on advanced material research tasks, translating high-level program requirements into concrete chemical synthesis matrix plans. Establish quality control, stoichiometry, morphologic, and particle-size distribution parameters using automated instrumentation and process analytical technology (PAT). Oversee advanced material characterization techniques including XRD, SEM/EDS, TGA/DSC, BET surface area analysis, laser diffraction particle sizing, and rheometry. Establish inert-atmosphere chemistry protocols (Schlenk line, glovebox operations) for air/moisture-sensitive inorganic and organometallic precursors. Work closely with composite, structural, and payload engineering teams to integrate synthesized powders into downstream manufacturing processes (e.g., sintering, additive manufacturing, slurry coatings). Guide, mentor, and review the work products of junior scientists, engineers, and lab technicians. Manage project deliverables, technical risk registers, schedule milestones, and research budgets for internal research and development (IRAD) or contracted customer programs. Prepare and present technical progress reports and design reviews to executive leadership, DoD stakeholders, and external technical partners. Proven track record in the synthetic scale-up of inorganic systems (e.g., borides, carbides, nitrides, oxides, or inorganic polymers). Hands-on experience with reactor design, reaction kinetics, particle nucleation/growth control, and powder processing (e.g., milling, spray drying, calcination). Strong expertise in air-free synthesis techniques (Schlenk lines, gloveboxes) and characterization tools (SEM, XRD, TGA). Qualifications Education: Ph.D. in Chemistry, Materials Science & Engineering, Chemical Engineering, Ceramic Engineering, or a related field with 3–5+ years of industry/postdoctoral experience; OR an M.S. degree with 6–8+ years of relevant scaled-synthesis experience. U.S. Citizenship: Required due to work within government facilities and access to export-controlled data. Preferred / Desired Qualifications Experience collaborating with government labs (e.g., AFRL, NRL, ORNL) on DoD or DARPA advanced materials programs. Direct experience with preceramic polymers or high-temperature structural ceramics for aerospace/defense applications. Knowledge of Design of Experiments (DoE) methodology and statistical process control (SPC) for chemical production routines. Active Secret or Top-Secret U.S. Security Clearance. Clearance Level No Clearance The salary range for this role is: $112,500 - $171,750 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