Does he have choices beside Syracuse, penn State OOS, and community college - that wouldn’t require parental loans?
If you tell us your budget and which state you’re in, we can suggest lower cost options that’d be OOS.
He’s clearly a strong student and with universities in limbo due to the FAFSA mess there may still be time to find something. And of course in May there’s the list of colleges that miscalculated yield and still have places.
Yes, and thank you.
3.7 GPA (weighted)
Test Optional
Some IB courses.
ECs: some summer pre-college programs for Engineering, College credits, summer intern.
I think his essays were good enough based on those summer pre-engineering programs experience. Engineering clubs. Started a Non-profit to help children in underserved communities. To name a few.
Accepted: Clemson (no aid, yet). New Haven University, and Widener both offered less than Syracuse.
Weight-Listed: Bucknell & Franklin & Marshall which were reach schools. My understanding is that the chances are slim getting off weight list and receiving aid.
Okay, some ideas…
Central Connecticut State University (I think they were accepting applications till March 30 so if he sends it today or tomorrow?)
Clarkson in Upstate New York (not sure they’d be within budget but solid match for him)
Slippery Rock University (in PA)
Western Michigan (in Kalamazoo)
UAkron
UMaine (tuition match)
UMass Lowell
UToledo
Youngstown State
In addition, look at scholarship deadlines (possibly contact Honors college/program?)
Another possibility is emailing PSU-UP and asking them whether, if he were to switch to PSU Behrend (STEM campus, lots of excellent engineering - some attend for 2+2 but many stay all 4 years) he could get a scholarship “making Psu Behrend and ultimatley PSU UP more affordable for your family, as it’s currently cheaper for him to attend Syracuse”. ← you’re not negotiating but the info is out there. They may not care but since they want to grow Behrend, ey, ball’s in their court. 
(Without any scholarship, COA at behrend would be around 40k but sometimes they offer scholarships to students to entice them.)