RF PCBA Design and Test Engineer

Worker Type

Job Description

Summary
We are seeking an RF PCBA Design and Test Engineer for the design integration and delivery of high-reliability RF/mixed-signal printed circuit assemblies for phased-array and advanced radar/communications products. You will own the PCB lifecyclefrom stack-up definition and layout governance through fabrication assembly bring-up release and test lifecycle for production circuit card assemblies (CCAs) and integrated RF systems.

Position Responsibilities

• Define multilayer hybrid dielectric RF stack- including impedance tables via strategy (blind/buried backdrill VIPPO) copper weights and plating/finish (ENIG/ENEPIG) to meet RF loss isolation and manufacturability targets.
• Partition boards for RF mixed-signal and high-speed digital with attention to shielding grounding return paths and thermal management (coins thermal vias heat spreaders).
• Establish and enforce RF layout rules (transitions launch geometries via fences cavity cutouts keep-outs) and high-speed constraints (length/phase matching crosstalk control reference continuity).
• Perform SI/PI/RF simulation and verification (e.g. ADS HFSS SIwave/Sigrity CST) to predict insertion loss VSWR/return loss coupling eye margins and PDN impedance.
• Lead schematic capture ECAD library governance (footprints/3D models) and DRC/DFM sign-off in Altium/Cadence/Mentor.
• Run formal design reviews drive closure of action items and maintain design histories BOMs and ECOs through PLM.
• Own fab and assembly drawing packages stack-up notes controlled impedance requirements coupons panelization and testability features.
• Collaborate with PCB fabs/CMs on builds (Class 3) negotiate tolerances and resolve issues (mask alignment plating thickness impedance yield lamination strategy).
• Plan and execute board bring-up; define acceptance tests and interface with RF test for S-parameters noise figure PAE ACPR/EVM and linearity (P1dB/IP3/AM-AM/AM-PM).
• Define implement and sustain acceptance tests for CCAs (Rx/Tx/control/power) with clear entry/exit criteria coverage metrics and pass/fail limits; maintain golden units and calibration artifacts.
• Architect automated test sequences (Python/LabVIEW/MATLAB or similar) for VNAs spectrum analyzers signal generators power meters oscilloscopes and RF switch matrices; integrate data logging serialization and dashboards; manage version control and CI where appropriate.
• Other duties as assigned

Basic Qualifications

• Bachelors degree in electrical engineering or related engineering field.
• 8 years in RF/microwave and mixed-signal PCB development for high-reliability products.
• Technical Depth:
• Proven expertise in RF board layout for L/S/C/X/Ku/Ka-band front-ends (LNAs PAs switches beamformers PLL/synth couplers/splitters).
• Hands-on with hybrid stack-ups controlled impedance design backdrill/HDI strategies and thermal/shielding practices.
• Tools: Proficiency with one or more ECAD suites (Altium Designer Cadence Allegro/OrCAD Mentor/Xpedition) and analysis tools (Keysight ADS Ansys HFSS/SIwave CST).
• Hands-on with RF measurements and analysis: S-parameters gain/NF linearity (P1dB/IP3) modulation metrics (EVM/ACLR) phase noise timing/synchronization PLL/synth chains PA/LNA/mixer characterization.
• Proficiency automating instruments and data pipelines (Python and/or LabVIEW; MATLAB a plus) using SCPI/IVI; experience with LAN/USB/GPIB control data historians/MES and dashboarding (e.g. Power BI/Tableau/SQL).
• Working knowledge of IPC-2221/2223 IPC-6012 IPC-A-600/-610 Class 3 ANSI/ESD S20.20 environmental/EMI test practices (e.g. MIL-STD-810/461 as applicable) calibration traceability and DoD documentation practices.
• Ability to obtain a DoD Top-Secret/SCI clearance.

Other Qualifications & Desired Competencies

• Masters degree preferred.
• Experience delivering phased-array TR modules beamforming IC integrations or wideband front-ends in production.
• Background in design for ruggedization and environmental screening (thermal cycling vibe/shock) and reliability analysis (derating FMEA).
• Familiarity with PLM (e.g. Arena/Windchill) manufacturing with domestic CMs and rapid RCCA/MRB/CCB processes.
• Exposure to mmWave packaging RF connectors/launches (SMPM/SMP/SEARAY/coax launches) and fixture design for S-parameter/over-the-air test.
• Certifications (IPC CID/CID) or equivalent PCB design credentials.
• Excellent technical communication supplier interaction and concise documentation skills.
• Track record leading cross-functional design efforts running reviews and mentoring engineers.
• Active Secret or TS preferred.

Physical Demands

• Ability to work in an office and manufacturing environment (Constant)

• Required to sit and stand for long periods; talk hear and use hands and fingers to operate a computer and telephone keyboard (Frequent)

Clearance Level

The salary range for this role is:

AeroVironment considers several factors when extending an offer including but not limited to the location the role and associated responsibilities a candidates 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 AeroVironments determination that it will be able to obtain an export license in a time frame consistent with AeroVironments 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: also encourage you to review our company website at to learn more about us.

Principals only need apply. NO agencies please.

About AV:

AV isnt for everyone. We hire the curious the relentless the mission-obsessed. The best of the best.

We dont just build defense technologywe redefine whats 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 Smithsonianbut were not building history were building whats next.

If youre ready to build technology that matterswith speed scale and purposetheres 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 datasexual orientation gender identity or other legally protected status.

ITAR