RPI gives merit aid to most students (94%) who don’t qualify for need-based aid (average $14K), but admissions have gotten tougher there over the last few years. I would think your S is in the ballpark, though.
WPI gives merit aid to about 87% of non-need students (average $12K) and is not quite as selective as RPI for admission.
Lafayette gives merit aid to about one-quarter of non-need students (average $13K), so getting money from them seems less likely if they base the decision on stats.
Bucknell gives very little merit aid. Don’t know about Lehigh, but suspect it’s not great. Both are pretty selective.
If your S is in the top 15% of his HS class, his test scores would probably qualify him for Provost Scholarship merit aid from Case Western of about $17K per year.
Be warned that some merit aid comes with a requirement to maintain a particular GPA, which may not be that easy in an engineering curriculum.
Even with these merit scholarships, you will have $35K or so to cover. You may want to look into some schools that are less expensive to begin with. Unless you are in-state for a public school, these are still not going to be cheap, but are less than full-pay at most privates.
Lower-tuition (especially if you are in-state!) schools with engineering that I am familiar with are
University of Delaware,
Rochester Institute of Technology,
University of Maryland (College Park),
University of Maryland Baltimore County,
Virginia Tech (already on your list)
and maybe (not as familiar)
Pitt
NC State
Clemson
Georgia Tech
Another option is a school with a co-op program that allows the student to earn some money while working a few semesters. This spreads the degree out over 5 years. Check out Drexel, Northeastern, and maybe Virginia Tech for co-op.
Best wishes