Overnight Injection Molding Process Engineer Jobs in Reston, VA

Worker Type

Job Description

Summary

AV is seeking a highly skilled Lead Mechanical Engineer to support the design, analysis, and development of advanced RF and electromechanical systems within the Hyper-RF division. This role is critical to delivering robust, manufacturable, and high-performance products across a range of applications including radar, wireless communications, phased array systems, and embedded electronics.
The ideal candidate brings deep expertise in mechanical design using SolidWorks, structural and thermal analysis using Ansys, and a strong working knowledge of product lifecycle management (PLM) processes within a disciplined engineering environment. This individual will work closely with cross-functional teams to transition designs from concept through production while ensuring compliance with quality and documentation standards.
Position Responsibilities

• Lead the mechanical design and development of complex assemblies and enclosures for RF and electronic systems

• Create detailed 3D models, drawings, and assemblies using SolidWorks

• Perform and interpret structural, thermal, and vibration analyses using Ansys AEDT/Mechanical or Solidworks Simulation to validate designs against requirements

• Collaborate with electrical, RF, FPGA, and software engineers to ensure seamless system integration

• Drive designs from concept through prototype, qualification, and production

• Develop and maintain complete technical data packages (TDPs), including drawings, BOMs, and analysis artifacts

• Ensure designs meet environmental, performance, and manufacturability requirements

• Support fabrication, integration, and test activities, including troubleshooting and root cause analysis

• Participate in and lead design reviews (PDR, CDR, etc.)

• Apply and enforce configuration management best practices, including revision control, change management (ECOs), and traceability

• Work closely with manufacturing and supply chain teams to support production readiness and cost optimization

• Mentor junior engineers and contribute to continuous improvement of engineering processes and standards

• Identify, draft, and execute environmental test plans according to system level requirements

Basic Qualifications (Required Skills & Experience)

• Bachelor's degree in Mechanical Engineering or related field

• 8+ years of relevant experience in mechanical design and analysis for complex systems

• Expert-level proficiency with SolidWorks (part modeling, assemblies, drawings, and PDM integration)

• Strong experience with Ansys for FEA structural analysis (stress, vibration, modal) and CFD thermal analysis (steady-state and transient)

• Demonstrated experience designing for ruggedized electronics packaging, including thermal management and structural integrity

• Experience with configuration management tools and processes (e.g., PDM/PLM systems, ECO workflows)

• Strong understanding of GD&T, tolerance stack-ups, and design for manufacturability (DFM)

• Experience supporting hardware through full lifecycle (design build test ? production)

• Ability to work in a fast-paced, multi-disciplinary team environment

Other Qualifications & Desired Competencies

• Experience with RF systems, phased arrays, or high-frequency electronics packaging

• Familiarity with passive and active thermal management techniques (heatsinks, fans, liquid cooling)

• Experience designing for environmental compliance (shock, vibration, thermal cycling, EMI considerations)

• Knowledge of materials selection for aerospace/defense applications

• Experience with MIL-STD environmental and mechanical requirements

• Familiarity with manufacturing processes (machining, sheet metal, additive manufacturing, injection molding)

• Experience working in a regulated environment (e.g., ISO 9001, AS9100)

• Experience with Solidworks EPDM is preferred

• Experience in designing tooling or test equipment is preferred

• Demonstrates competency in solving basic structural dynamics problems

• Demonstrates understanding of engineering configuration management processes and material properties

• Demonstrates understanding of environmental testing, including shock and vibration

• Able to excel in a fast-paced, deadline-driven environment, where small teams share a broad variety of duties

• Displays strong initiative and drive to accomplish goals and meet company objectives

• Takes ownership and responsibility for current and past work products

• Is committed to learning from mistakes and driven to improve and enhance performance of oneself, others, and the company

• Focuses on teamwork and puts the success of the team above one's own interests

Physical Demands
Ability to work in an office and production 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

The salary range for this role is:

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