Senior Hardware Electrical Engineer Job at AV in San Diego

BlueHalo (formerly AeroVironment) is a leading autonomous vehicle company developing cutting‑edge RF‑based Counter‑Unmanned Aircraft Systems (C‑UAS) platforms. The company is at the forefront of defense technology innovation, creating solutions that protect critical infrastructure and personnel.

Role Overview

We are seeking a Senior Hardware Electrical Engineer to join our dynamic Engineering Team as an integral contributor to our RF‑based Counter‑UAS platforms. The ideal candidate will drive development, integration, and testing of advanced technologies while supporting our transition from development to production. The role requires a strong electrical engineering background with demonstrated expertise in hardware production, late‑stage development, postproduction diagnostics, and rework of sensitive electronics.

Key Responsibilities

• Provide direct, hands‑on support for product manufacturing across multiple programs and product lines.
• Test and troubleshoot hardware systems through analysis of schematics, component datasheets, and PCB layout, driving root‑cause analysis and resolution of process issues, non‑conformances, and yield concerns.
• Utilize oscilloscopes, multimeters, and precision test equipment for circuit analysis and troubleshooting.
• Rework failed PCB assemblies using soldering iron and hot air reflow.
• Maintain and improve existing manufacturing processes, tooling, and work instructions to support scalable and efficient production.
• Coordinate design‑for‑manufacturability (DFM) efforts with R&D, systems, and hardware engineering teams to ensure seamless development‑to‑production transitions.
• Develop and enhance automated test systems to improve efficiency and reliability.
• Conduct hands‑on evaluation and validation of system components.
• Track and report key production metrics including throughput, cycle time, quality yield, and material availability.
• Participate in capital equipment planning and facility layout improvements to support current and future production demands.
• Support PM with data tracking and reporting to support SIOP and engineering management calls.

Basic Qualifications

• Bachelor’s degree in Electrical Engineering or related field required (equivalent combination of education, training, and experience acceptable).
• Minimum of 8–12 years of relevant experience.
• Proficient with office software, computer‑based productivity tools, and other software tools relevant to the role.
• Experienced using Altium Designer for schematic capture and PCB layout.
• Experience in one or more areas: Radio Frequency (RF), embedded control, FPGA.
• Experience with power electronics, including motors and battery technology (lead acid, nickel‑metal hybrid, lithium‑ion).
• Demonstrated ability to troubleshoot complex systems.
• Familiarity with common industry protocols (LVDS, I2C, HDMI, UART, SPI, CAN, USB).
• Knowledge of engineering fundamentals, mathematics, physics, and material properties.
• Some travel may be required in support of flight test operations (up to 30%).
• Must have a clean driving record.

Preferred Qualifications & Desired Competencies

• Master’s degree in Electrical Engineering or related discipline.
• 7+ years of experience preferred.
• Working knowledge of AS9100, IPC standards, and quality management systems.
• Familiarity with PLM tools and digital thread initiatives.
• Experience with RF systems, electronic warfare, or counter‑UAS technologies.
• Strong understanding of work order management, lead time management, theory of constraints, lean six sigma, and demand‑supply matching.

Physical Demands

• Ability to work in an office environment.
• Required to sit and stand for long periods; talk, hear, and use hands and fingers to operate a computer and telephone keyboard.

Clearance Level

No Clearance

Salary Range

$107,370 – $152,250

ITAR Requirement

This position requires access to information subject to ITAR and/or EAR compliance. Applicants must qualify as a U.S. person under ITAR/EAR, or be approved for an export license. U.S. citizenship is required for certain contract obligations.

Benefits

We offer an excellent benefits package including medical, dental, vision, 401(k) with company matching, a 9/80 work schedule, and a paid holiday shutdown. For more information, visit our benefits page.

Equal Employment Opportunity

We are proud to be an EEO/AA Equal Opportunity Employer. Qualified applicants will receive fair and impartial consideration without regard to race, sex, color, religion, national origin, age, disability, protected veteran status, or genetic data. All designations of gender identity or sexual orientation are protected.