Lead Sr. Optical Mfg. Engineer

Worker Type

Regular

Job Description

 

About The Role

The Manufacturing Engineering Team within our Space Technologies area is responsible for developing and scaling assembly, integration, and test operations for next-generation space systems, including optical payloads, laser communication terminals, and space-qualified hardware for satellite and orbital applications.

As a critical member of this team, the Lead Optical Manufacturing Engineer will serve as the technical leader translating optical system designs (e.g., for laser comms, imaging, or stabilization payloads) from development into a sustainable, high-yield production environment. You will collaborate closely with design engineers, test engineers, systems engineers, and cross-functional teams to establish optical manufacturing processes and work instructions—from component assembly through final integration and qualification for space environments.

This role is ideal for hands-on engineers who thrive on building and testing complex, high-precision optical products in cleanroom settings and take a methodical, innovative approach to pioneering and scaling production for defense and space missions.

This is a full-time, in-office position based in our Albuquerque, NM facility.

Impact You'll Own

• Lead a team of highly motivated Manufacturing Engineers and Sr. Technicians.
• Support the Assembly, Integration, and Test (AI&T) of optical payloads and space-qualified systems, including laser communication terminals and imaging/stabilization hardware
• Develop/document optical assembly procedures and work instructions, including precise metrology, alignment (warm/cold), bonding, and performance testing in simulated space conditions
• Design, develop, and implement mechanical/electrical tooling, fixtures, and Ground Support Equipment (GSE) for optical assembly and test in cleanroom environments
• Perform analysis of measured data for alignment, calibration, characterization, and environmental qualification, monitor production metrics and yield
• Drive timely resolution of non-conformances (NCRs), conduct root cause analysis, implement corrective actions, and lead continuous improvement initiatives
• Provide critical Design for Manufacturability (DFM) and Design for Assembly (DFA) feedback to optical, mechanical, and systems design teams
• Provide technical oversight for external vendors and suppliers involved in optical component fabrication, coatings, and assembly
• Participate in training production technicians to transition manufacturing lines from R&D/prototyping to scaled production
• Recommend facilities, capital equipment, and process improvements to scale space-qualified manufacturing operations

What You Bring

• Bachelor's degree in Optical Engineering, Manufacturing Engineering, Mechanical Engineering with a focus in Optics (Optomechanical), Aerospace Engineering, Electrical Engineering, or a related technical field
• 10+ years of total relevant experience, of which 3+ years directly in the assembly, integration, alignment, and test of complex optical instruments, telescopes, laser systems, micro-electronics, high precision wafer fabrication, or space-based payloads
• Experience leading a team of 4-6 Manufacturing Engineers and Sr. Technicians to develop the manufacturing area into a world class, ISO 5 or better Clean Room, Optical Payload Mfg. Environment
• Hands-on experience with complex optomechanical assembly, precision alignment, integration, and bonding in cleanroom environments (ISO Class 5 or better)
• Experience leveraging technical software for design, analysis, and test (e.g., Zemax, MATLAB, Python, LabView and/or C/C++)
• Expertise in reading technical drawings and using SolidWorks or equivalent CAD software to develop tooling and fixtures
• Experience defining and implementing manufacturing processes in a production environment, including New Product Introduction (NPI) for high-reliability systems
• Solid interpersonal skills and a collaborative, hands-on attitude for working effectively with cross-functional, multi-disciplinary teams
• Excellent attention to detail and technical writing skills for creating detailed procedures, test plans, and data summaries

What Makes You Stand Out

• Experience with space-qualified optical systems, laser communications, directed energy optics, fiber optics, and/or hyperspectral/multispectral imaging payloads
• Experience implementing successful continuous improvement methodologies (e.g., Lean, Six Sigma) in high-reliability manufacturing
• Familiarity with Manufacturing Execution System (MES) and Product Lifecycle Management (PLM) software
• Experience across the space flight program lifecycle (design through on-orbit operations and qualification)
• Knowledge of MIL-STD, NASA, or DoD standards for space hardware
• Additional education or certifications in relevant engineering or scientific fields

Clearance Level

 

Top Secret

The salary range for this role is:

$106,500 - $151,200

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

U.S. Citizenship is required. Secret or Top Secret clearance, or the ability obtain a clearance is desired.