Mechanical Engineer - HyperRF

OVERVIEW

AV is seeking skilled Mechanical Engineers 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 ofapplications 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 ofproduct 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.

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 AnsysAEDT/Mechanical or Solidworks Simulationto 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, includingrevisioncontrol, 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

REQUIRED QUALIFICATIONS

• Bachelor’s degree in Mechanical Engineeringor 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 forFEA structural analysis (stress, vibration, modal) andCFDthermal analysis (steady-state and transient)

• Demonstrated experience designing forruggedizedelectronics 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

PREFERRED QUALIFICATIONS

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

• Familiarity withpassive and activethermal 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)