Mechanical Engineer

About Aventra

Aventra Defense Systems is a defense technology company developing and delivering autonomous aerial systems for the U.S. government and allied partners. We operate at the intersection of advanced hardware, software, and national security — designing, building, and fielding systems that perform in the world’s most demanding environments.

We are a mission-driven team moving at startup speed with defense-grade accountability. Our programs span contracted deliveries, government demonstrations, and ongoing system development — and our pace reflects the urgency of the problems we’re solving.

Position Overview

Aventra Defense Systems is seeking a mid-level Mechanical Engineer to own the design and productization of subsystems within our Piranha high-altitude platform — from early prototype through a field-ready, producible design. This is a hands‑on, individual-contributor role with clear subsystem ownership: you’ll take a specific piece of the system and drive it from where it stands today toward a production‑ready product. Just imagine seeing the hardware you designed flying in the stratosphere.

Key Responsibilities

Subsystem Design

• - Turn product requirements documents into reality! Own the mechanical design of an assigned high‑altitude subsystem, building on and leveling up existing prototypes.
• - Conduct rigorous FEA (structural, thermal, and vibration) to ensure your designs survive the extreme temperatures and dynamic loads of high‑altitude flight.
• - Design for reliability, manufacturability (DFM), and cost at the subsystem level.
• - Experience the joy of rapid iteration—design a part in CAD, 3D print it in our shop, and have a finished prototype in your hands days later to test.
• - Run bench‑level and field testing to validate performance across extreme environmental and altitude conditions utilizing thermal/vacuum chambers and strain gauges to make sure your design works.
• - Design and implement tests across a variety of systems and environments.
• - Peer review other engineers' work.
• - Conduct trade studies to understand the state of the art and industry best practices.

Integration & Test

• - Integrate your subsystems with electrical, aero, and software teams.
• - Assist with flight test instrumentation setup and post‑test data collection.
• - Help maintain test equipment, fixtures, and lab organization.
• - Test your design in the field and watch it fly!

Productization and Manufacturing

• - Drive the transition from a working prototype to a rugged, field‑ready, producible design.
• - Perform detailed tolerance stack‑up analysis and apply GD&T to ensure complex assemblies fit flawlessly every time they come off the line.
• - Identify and resolve manufacturing, sourcing, and reliability bottlenecks before they reach production.
• - Support production handoff and work closely with machinists and external vendors to get your hardware built.

Integration & Iteration

• - Coordinate seamlessly with electrical, software, and aero teams, packaging complex avionics and integrating actuation, control, and sensor feedback interfaces.
• - Assist with flight test instrumentation setup, post‑test data collection, and lab organization.
• - Test your design in the field and watch it fly!
• - Dive into post‑flight test data to root‑cause anomalies, then rapidly incorporate field feedback into iterative design improvements.

Documentation & Process

• - Maintain accurate models, drawings, BOMs, and design documentation
• - Support design review processes and component sourcing research
• - Analyze and learn from failures and document so the organization doesn't have to learn the same lesson twice.

Minimum Qualifications

• - Bachelor's degree in Mechanical Engineering, Aerospace Engineering, or related field
• - 3-6 years of industry experience in mechanical design, ideally including high‑altitude, pneumatic/fluidic, or release/deployment mechanisms
• - Proficiency in CAD tools such as SolidWorks or OnShape, with a demonstrable portfolio of designs you've taken from concept through hardware
• - Hands‑on prototyping and testing experience
• - US Citizen with ability to obtain and maintain security clearance

Preferred Qualifications

• - Experience in aerospace, defense, or other high‑reliability industries
• - Exposure to embedded systems or sensor integration
• - Startup or small‑company experience
• - Familiarity with relevant military standards

$120,000 - $185,000 a year

Compensation Package

• - Competitive salary commensurate with experience
• - Generous health coverage for employee and family, premium fully covered
• - 4% 401k match
• - PTO and Sick Leave

Travel & Work Environment

Travel Requirements

• - Travel up to 25% to customer sites, and field test locations
• - Ability to work in austere field conditions and military operational environments
• - Flexibility to support urgent operational requirements and schedule changes

Work Environment

• - In‑person role based in Herndon, VA
• - Collaborative environment supporting critical national security missions
• - Direct support to warfighter capabilities and mission success

Aventra Defense Systems, Inc is a venture‑backed startup building scalable, precision‑guided capabilities for the next generation of combat. We are assembling a team of engineers and operators who believe in speed, simplicity, and delivering real capability to the field—not just PowerPoint slides.