Senior Engineer - Composite Materials

At EDGE bold ideas are engineered into technologies that protect, improve and save lives.

Headquartered in the United Arab Emirates, EDGE is a leading advanced technology group working at the forefront of defence and emerging technologies. Spanning more than 35 specialised companies and multiple centres of excellence, we are purpose-built to move fast. Free from heavy legacy processes, we give our people the autonomy, accountability, and agility to bring breakthrough technologies from concept to reality.

Based in Abu Dhabi, a globally connected hub at the crossroads of Europe, Asia, Africa, and the Middle East, EDGE is home to a truly multicultural community where bold ideas thrive, and the future is shaped.

Together, we are shaping the future.

HALCON is seeking an experienced Senior Engineer – Composite Materials to join our Rocket Propulsion team. In this role, you will lead the design, development, analysis, and qualification of advanced composite structures that are critical to the performance and reliability of next-generation solid rocket motor systems.

This is an opportunity to work on cutting-edge aerospace and defense technologies, contributing to the development of composite motor cases, nozzle structures, thermal protection systems, and propulsion hardware from concept through qualification and production.

• Lead the design and structural analysis of composite components for solid rocket motors, including motor cases, nozzle structures, thermal insulation systems, and airframe components.
• Develop and qualify composite manufacturing processes such as filament winding, hand lay-up, tape winding, and automated fiber placement (AFP).
• Perform structural assessments using Finite Element Analysis (FEA) and Classical Laminate Theory (CLT) to validate designs and establish structural margins.
• Support rocket motor development programs through material selection, insulation design, and propulsion system integration activities.
• Define and execute composite material qualification and testing plans in accordance with aerospace and defense standards.
• Collaborate with propulsion, thermal, mechanical, manufacturing, and quality teams to ensure successful product development and integration.
• Support prototype builds, proof testing, hydrostatic testing, burst testing, and qualification campaigns.
• Review supplier qualifications, process specifications, and composite manufacturing data packages.
• Mentor junior engineers and provide technical guidance on composite design, manufacturing, and inspection activities.
• Develop engineering specifications, manufacturing documentation, technical reports, and design review presentations.
• Evaluate emerging materials, manufacturing technologies, and innovative structural concepts to support future propulsion programs.

• Bachelor's degree in Aerospace Engineering, Mechanical Engineering, Materials Engineering, Polymer Engineering, or a related discipline

• Minimum 8 years of experience in composite structures engineering within aerospace, defense, space, or advanced manufacturing environments. Proven experience designing and developing composite structural components for high-performance applications.
• Hands-on experience with:
  • Filament winding
  • Hand lay-up
  • Automated Fiber Placement (AFP)
  • Automated Tape Layup (ATL)
  • Tape winding processes

• Strong knowledge of composite materials, structural mechanics, and manufacturing processes.
• Experience with composite structural analysis using:
  • Abaqus
  • Nastran
  • ANSYS or equivalent FEA tools
• Proficiency in Classical Laminate Theory (CLT) and composite failure analysis.
• Experience with material qualification, testing, and certification activities.
• Familiarity with ASTM standards, CMH-17/MIL-HDBK-17, and aerospace quality requirements.
• Understanding of propulsion systems, pressure vessels, rocket motor structures, or related aerospace applications is highly desirable.

Candidates with experience in one or more of the following areas are strongly encouraged to apply:

• Solid Rocket Motors (SRM)
• Missile Systems
• Launch Vehicles
• Space Propulsion
• Composite Pressure Vessels
• Aerospace Primary Structures
• Defense Systems Development

Launched in November 2019, the UAE's EDGE is one of the world's leading advanced technology groups, established to develop agile, bold and disruptive solutions for defence and beyond, and to be a catalyst for change and transformation. It is dedicated to bringing…