Senior Manufacturing Engineer - Space Technologies

The Space Tech Senior Manufacturing and Process Engineer is responsible for developing, implementing, qualifying, optimizing, and sustaining manufacturing processes for precision optical and electromechanical systems intended for space applications. Products include fast steering mirrors (FSMs), delicate optical components, optical bench assemblies, and integrated optical systems requiring controlled assembly, alignment, and performance verification.

This role serves as a technical lead within Manufacturing Engineering, partnering with Design Engineering, Optical Engineering, Systems Engineering, Quality, Supply Chain, Operations, and Test Engineering to translate product requirements into repeatable production processes. The engineer will lead process development and continuous improvement, support research and development and new product introduction, resolve complex production issues, and mentor engineers and manufacturing personnel while improving quality, yield, cost, safety, and delivery.

• →Develop, document, validate, and sustain assembly, integration, alignment, and test processes for space optical systems, precision optomechanical assemblies, and fast steering mirrors.
• →Lead manufacturing readiness activities from prototype development through design transfer, qualification builds, and production transition; identify process maturity gaps and implement closure plans.
• →Review designs for manufacturability, assembly, alignment access, inspection, testability, serviceability, and cost; address tolerance stacks, datum strategies, and sensitivity to handling and assembly variation.
• →Establish methods for handling, cleaning, protecting, packaging, and storing delicate optics and coated surfaces; define contamination, foreign object debris (FOD), and electrostatic discharge (ESD) controls appropriate to the hardware.
• →Develop controlled bonding and curing processes, including surface preparation, adhesive mixing and dispensing, bond-line control, fixturing, shimming, cure parameters, and witness coupons or other verification methods as required.
• →Develop FSM assembly processes for mirrors, mounts, flexures, actuators, coils, sensors, wiring, and cables; control polarity, cable routing, keep-out zones, flexure protection, and repeated handling during adjustment.
• →Partner with Optical and Test Engineering to establish alignment sequences, metrology setups, reference datums, adjustment methods, and acceptance criteria for optical and electromechanical performance.
• →Develop repeatable measurement and test methods for applicable requirements, such as mirror flatness, surface figure, wavefront error, boresight, line-of-sight stability, range of motion, pointing accuracy, repeatability, and dynamic response.
• →Create and maintain controlled work instructions, process specifications, standard operating procedures, process flow diagrams, travelers, assembly aids, bills of material, routings, and tooling requirements.
• →Design or coordinate precision fixtures, alignment tooling, optical handling aids, gauges, and test equipment; ensure production aids protect hardware and support repeatable assembly and inspection.
• →Support equipment selection, installation and operational qualification, performance qualification where required, calibration, measurement-system assessment, and preventive maintenance planning.
• →Establish process parameters, in-process inspection points, acceptance criteria, traceability requirements, and production controls; maintain process failure mode and effects analyses (PFMEAs) and associated control plans.
• →Investigate nonconformances, optical performance degradation, bond failures, alignment drift, yield losses, and process escapes; lead structured root-cause analysis and verify corrective-action effectiveness.
• →Analyze process and test data to identify variation, constraints, rework drivers, and capacity needs; apply Lean Manufacturing, Six Sigma, and other appropriate improvement methods.
• →Support first article inspections, capability studies, process validation, qualification testing, and production readiness reviews; assess alignment and functional performance before and after environmental testing as required.
• →Partner with Quality Engineering on material review board activities, inspection methods, corrective actions, and disposition support; evaluate rework methods for effects on optical surfaces, bonds, and alignment.
• →Support supplier development and qualification of optics, coatings, precision-machined hardware, adhesives, electromechanical components, and outsourced processes; translate requirements into receiving and acceptance controls.
• →Assess manufacturing impacts of design, material, chemistry, tooling, software, and process changes; define supporting data, requalification needs, documentation updates, and implementation tasks.
• →Develop training using mock-ups, representative hardware, and practical demonstrations; mentor Manufacturing/Process Engineers I and II and train technicians in optical handling, assembly, alignment, and process discipline.
• →Participate in design reviews, risk assessments, production readiness reviews, and program reviews; communicate manufacturing risks, recovery plans, and readiness status.
• →Ensure manufacturing processes meet applicable engineering, quality, safety, environmental, and program requirements; support urgent production troubleshooting and perform other duties as assigned.

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

• Bachelor’s degree in Mechanical Engineering, Manufacturing Engineering, Optical Engineering, Electrical Engineering, Industrial Engineering, or a related technical field.
• Typically 3–7 years of relevant manufacturing or process engineering experience, or an equivalent combination of education and experience.
• Demonstrated experience developing and sustaining processes for precision optical, optomechanical, or complex electromechanical products and assemblies.
• Hands-on experience with delicate component handling and precision assembly, alignment, metrology, or performance testing.
• Experience with new product introduction, production transition, design for manufacturability, and cross-functional technical projects.
• Working knowledge of controlled bonding, cleanliness, contamination prevention, precision tooling, and process verification applicable to optical hardware.
• Strong knowledge of root-cause analysis, corrective action, process capability, and continuous-improvement methods.
• Experience creating and maintaining manufacturing documentation and product traceability in a controlled environment.
• Ability to interpret engineering drawings, geometric dimensioning and tolerancing (GD&T), specifications, bills of material, and test requirements.
• Strong analytical, problem-solving, communication, and organizational skills; ability to work effectively with engineering, operations, quality, supply chain, and external suppliers.
• Proficiency with Microsoft Office or equivalent productivity tools.
• U.S. citizenship is required.
• Ability to obtain and maintain a Department of Defense (DoD) security clearance.

• Experience manufacturing space-flight optical hardware, fast steering mirrors, beam steering mechanisms, optical payloads, or precision pointing systems.
• Experience with optical alignment and metrology tools such as interferometers, autocollimators, alignment telescopes, coordinate measurement systems, and optical power or beam measurement instruments.
• Experience with FSM actuator and sensor integration, flexure assemblies, dynamic characterization, and collaboration with controls and test teams.
• Familiarity with thermal vacuum, vibration, shock, and environmental stress screening (ESS), including performance verification and alignment retention across test exposures.
• Experience with cleanroom operations, optical cleaning, adhesive qualification, cure verification, and material selection for contamination-sensitive or vacuum applications.
• Experience with ERP, MRP, MES, PLM, or manufacturing document-control systems, including Factory Logix or comparable platforms.
• Experience with CAD and the design of precision assembly, alignment, handling, and test fixtures.
• Experience with automation, automated data collection, test scripting, or manufacturing systems integration.
• Experience in aerospace, defense, or another highly regulated manufacturing environment; familiarity with AS9100, ISO 9001, and applicable IPC workmanship requirements.

• Precision optical and electromechanical process development
• Design for manufacturability, assembly, alignment, and test
• Contamination control and delicate optics handling
• Structured problem solving and quality ownership
• Process validation, risk management, and continuous improvement
• Data analysis and technical decision-making
• Cross-functional collaboration and clear technical communication
• Mentoring, technician training, and knowledge transfer

• Ability to work in office, engineering laboratory, cleanroom, and manufacturing environments.
• Ability to wear required personal protective equipment, cleanroom garments, and ESD protection.
• Ability to perform or support precision assembly and inspection using microscopes, optical instruments, and production equipment, with or without reasonable accommodation.
• Ability to occasionally lift, carry, or manipulate materials and equipment within applicable safety limits, with or without reasonable accommodation.
• Ability to stand, walk, bend, and reach as required by the work, with or without reasonable accommodation.
• Ability to support occasional off-shift or extended-hours production activities.
• Travel may be required based on business needs.