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Staff Mechanical Engineer- sUAS

Aurora Flight Sciences and Careers
Manassas, VA Full Time
POSTED ON 1/1/2026
AVAILABLE BEFORE 3/1/2026

Staff Mechanical Engineer- sUAS

Position Overview

At Aurora Flight Sciences, we design, build, and fly advanced aircraft and enabling technologies from concept to reality. We are searching for a talented and self-motivated Staff Mechanical Engineer- sUAS to help us create the future of flight. Responsibilities will include but not be limited to the following:

Responsibilities

  • Perform mechanical design of novel aircraft, small UAS and supporting systems.
  • Conduct rapid prototype development, manufacturing, and integration.
  • Perform developmental and qualification testing, troubleshooting, and data analysis.
  • Collaborate with other engineering disciplines in planning, development, and test of systems to ensure software and hardware performance and compatibility.
  • This position is based at Aurora’s Manassas, VA location and is 100% on-site.

Minimum Requirements

  • Bachelors Degree in Mechanical Engineering, Aerospace Engineering or other relevant 4-year engineering degree from an accredited university.
  • Minimum typically of five years of experience in aircraft or small UAS development.
  • Proficiency in mechanical design for aerospace applications.
  • Proficiency with CAD tools including SolidWorks, CATIA V5 and/or 3DX.
  • Able to travel for up to 2 weeks at a time approximately 4 times per year.
  • Must be a US Citizen and be able to obtain a security clearance.

Preferred Requirements

  • Proficiency with test and data analysis tools such as LabView, MATLAB, Excel, and Python.
  • Knowledgeable in all aspects of the aircraft and small UAS development life cycle from initial design concepts to manufacturing, integration, and test.
  • Working knowledge of electrical systems and software development and test methods.
  • Demonstrated ability to troubleshoot complex problems on the fly while supporting flight test operations.
  • Self-motivator with demonstrated performance in a small team environment.
  • Experience with metal and/or composites fabrication, assembly, and integration.
  • Proficiency operating manual and CNC mills and lathes, laser cutters, waterjets, and 3D printers.
  • Familiar with UAV autopilot software such as PX4 (preferred), or Ardupilot.
  • Experience with electromechanical system design and analysis.
  • Experience with embedded systems programming, verification, and test.
  • Radio Controlled (R/C) pilot with experience in custom R/C aircraft design, build, assembly, and flight operations.
  • Holds current FAA Part 107 Certificate.
  • Submitting a design or project portfolio is highly encouraged.

Physical Requirements

  • Ability to lift 35 pounds
  • Ability to be on-site weekly at our Manassas, VA site

Salary Range (Annualized USD)

  • Minimum Range: $68,000.00 to $120,000.00
  • Maximum Range: $84,000.00 to $150,000.00

Aurora Company Overview

Aurora Flight Sciences, a Boeing Company, is a leader in the development and manufacturing of advanced unmanned systems and aerospace vehicles. Our mission is to apply autonomy and robotics to the development, production, and operation of advanced aircraft. During the last three decades, Aurora has designed, rapid-prototyped, and flown an average of one new vehicle a year for both government and commercial customers. Now, as an independent subsidiary of Boeing, Aurora’s innovation is combined with Boeing’s size and strength, creating an unprecedented opportunity to shape the future of aerospace systems.

Equal Opportunity Employer

Aurora Flight Sciences, A Boeing Company, is an Equal Opportunity Employer. Employment decisions are made without regard to race, color, religion, national origin, gender, sexual orientation, gender identity, age, physical or mental disability, genetic factors, military/veteran status or other characteristics protected by law.

Aurora Total Rewards

At Aurora Flight Sciences, a Boeing Company, we strive to deliver a Total Rewards package that will attract, engage and retain the top talent. Elements of the Total Rewards package include competitive base pay and variable compensation opportunities. Aurora Flight Sciences provides eligible employees with an opportunity to enroll in a variety of benefit programs, generally including health insurance, flexible spending accounts, health savings accounts, retirement savings plans, life and disability insurance programs, and a number of programs that provide for both paid and unpaid time away from work. The specific programs and options available to any given employee may vary depending on eligibility factors such as geographic location and date of hire. Please note that the salary information shown is a general guideline only. Salaries are based upon candidate experience and qualifications, as well as market and business considerations.

Salary : $68,000 - $150,000

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