Structures Designer​/Senior

Position Overview

At Aurora Flight Sciences, we design, build, and fly advanced aircraft and enabling technologies from concept to reality. We are searching for a talented and self‑motivated Structures Designer‑Staff/Senior to help us create the future of flight.

• Provide the first line of technical authority within the design team, approving design concepts and determining technical objectives for projects.
• Lead by example, mentoring and guiding junior engineers while working independently for extended periods.
• Create airframe structural configuration layouts and detailed designs, including preliminary sizing, joint layouts, and interface boundary definitions for parts and assemblies, working with both metallic and composite materials.
• Develop and maintain CAD models and drawings of installations, assemblies, and detail components, ensuring strict adherence to structural integrity, interface boundaries, weight, and cost targets.
• Conduct design reviews and validate product structures to ensure components meet functional, fit, and form requirements.
• Assume ownership of project execution and integration, leading teams of engineers to deliver against program budgets and deadlines.
• Coordinate with stress, manufacturing, procurement, and quality control teams to mature designs from initial conception to full‑scale production.
• Track weekly progress and maintain project documentation to ensure alignment with program milestones.
• Collaborate effectively with manufacturing and tooling teams for prototyping, material selection, and production strategies, particularly for composite components.
• Prepare and present technical and programmatic data during Preliminary Design Reviews (PDRs) and Critical Design Reviews (CDRs).
• Offer technical guidance and mentorship to team members, including junior designers, to achieve high‑quality deliverables.

• Ability to obtain a US Security Clearance requiring US Citizenship.
• Bachelor’s Degree in Mechanical Engineering, Aerospace Engineering, or related discipline.
• Minimum of 5 years of experience in aerospace or related fields.
• Competence with CAD software, particularly CATIA V5, Smar Team, or similar product data management systems (e.g., Enovia LCA or PDM).
• Knowledge of industry standards relating to composite component design, manufacturing, repair, and assembly (specific to aerospace).
• Proficiency with Microsoft Office 365 (Excel, Word, and PowerPoint).
• Strong verbal and written communication skills with a collaborative mindset.

• Expertise in CATIA V5 modules (Generative Surface Design, Part Design, Assembly); experience with Unigraphics or Siemens NX will be considered.
• Advanced knowledge of composite material structures, including design, stacking sequences, lamination theory, bonded assemblies, and post‑cure machining operations.
• Familiarity with prototype and rate production, including exposure to manufacturing tooling design, planning, and hands‑on fabrication.
• Knowledge of ASME Y14.5 and related tolerance analysis techniques.
• Familiarity with Model-Based Definition (MBD), ASME Y14.41 methods, and CATIA V5 FTA for functional tolerancing and annotations.
• Strong foundation in manufacturing and development of aerospace structural components and assemblies.

• Ability to work on‑site on a weekly basis at our Manassas, VA or Cambridge, MA locations.

• Minimum Range: $92,000.00 to $
• Maximum Range: $ to $

Aurora Flight Sciences provides eligible employees with enrollment options in health insurance, flexible spending accounts, health savings accounts, retirement savings plans, life and disability insurance, and various programs that offer paid and unpaid time off. The salary information shown is a general guideline only. Salaries are based on candidate experience and qualifications, as well as market and business considerations.

Aurora Flight Sciences, a Boeing Company, is an Equal Opportunity Employer. Employment decisions are made without regard to race, color, religion, national origin, gender, sexual orientation, gender identity, age, physical or mental disability, genetic factors, military/veteran status or other characteristics protected by law.