Sr. Mechanical Integration Engineer - Space Technologies

Worker Type Regular Job Description We are seeking a mid-career Mechanical Integration Engineer to provide engineering design, drafting and assembly support to diverse R&D programs and small-volume production contracts. Projects vary from packaging high reliability electronics subsystems to opto-mechanical mechanism design such as gimbal and steering mirror systems. A Mechanical Integration Engineer bridges the gap between product design and production. They design mechanical components, work with mechanical parts and assemblies on the factory floor for first time builds and improve build efficiency with the Manufacturing engineers. They also collaborate with lead Mechanical engineers, Technical leads and Procurement personnel to finalize drawings, work with Machine shops on technical questions and define inspection plans for critical parts. The role ensures parts are meeting design intent, can be easily manufactured for repeatable lots, and efficiently assembled while maintaining top-tier quality standards. Position Responsibilities Design for Manufacturing (DFM): Modify or refine mechanical designs and 3D CAD models to ensure they can be efficiently mass-produced Process Integration: Determine the optimal arrangement of assembly lines and production cells to maximize throughput and minimize waste Tooling & Equipment: Design custom jigs, fixtures, and mechanical tooling to support new product launches and line setups Quality Control: Establish testing protocols, analyze mechanical tolerances, and use methods like PFMEA to prevent defects Troubleshooting & Optimization: Perform root-cause analysis on equipment breakdowns or production bottlenecks, and apply Lean or Six Sigma principles to resolve them. Cross-Functional Collaboration: Serve as the technical liaison between product designers, supply chain vendors, and assembly line operators. Other duties as assigned Basic Qualifications (Required Skills & Experience) Bachelor of Science in Mechanical Engineering or Aerospace engineering 2+ years' experience in one or more of the following areas: Software Proficiency: design using CAD software, ideally experience with SolidWorks Technical Knowledge: Understanding of Geometric Dimensioning and Tolerancing GD&T, various material properties, and manufacturing processes (e.g., CNC, machining). Space hardware design, integration, and test Strong technical writing skills applicable to engineering documentation (analysis reports, specifications, requirements documents, etc.). Process Methodologies: Experience with Lean Manufacturing, Kaizen, and Root Cause Analysis. Other Qualifications & Desired Competencies 5-8 years' experience in mechanical engineering of space systems Strong verbal communication skills needed for customer interaction at design reviews, supplier interaction, etc. Ability to quickly adapt to various projects and types of work and to work several projects simultaneously while managing time and priorities Ability to work independently or as part of a development team Experience and willingness to be hands on during hardware assembly, integration, and test Current US security clearance Physical Demands Ability to work in an office and manufacturing environment (Constant) Required to sit and stand for long periods; talk, hear, and use hands and fingers to operate a computer and telephone keyboard (Frequent) 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.