Weld Engineer - Launch Vehicle Structures

LEAP Weld Engineer - Launch Vehicle Structures Broomfield, CO Full time

The Launch Vehicle Structures Weld Engineer is responsible for developing, qualifying, and sustaining all welding and joining processes used in the fabrication of flight propellant tanks and unpressurized structures for LEAPS suborbital and orbital launch vehicles. This role owns weld process design, procedure qualification, tooling collaboration, inspection coordination, and production support ensuring welds meet structural, fracture, and quality requirements for flight hardware.

This role collaborates with weld technicians, fixture design engineers, NDE, and stress teams to deliver repeatable, certifiable, and flight-worthy welds.

LEAP is transforming space logistics with rapid-response, mass producible launch solutions designed to eliminate bottlenecks in space access. Leveraging proprietary propulsion technology and modern manufacturing techniques, LEAP delivers scalable and cost-effective, launch solutions for national security, commercial payload deployment, and global point-to-point logistics applications.

• Develop, qualify, andmaintainwelding procedures (WPS/PQR) for propellant tanks and pressure vessels, ensuring weld processes are certified, repeatable, and compliant with structural, fracture-control, and pressure-vessel requirements for flight hardware
• Define weld joint designs, fit-up requirements, and weld sequencing in collaboration with design and structures teams, ensuring load paths, distortion control, and structural margins aremaintainedwhile enabling repeatable, high-quality production welds
• Establish process windows, parameter control, and acceptance criteria, resulting in reduced variability, fewer weld defects, and improved first-pass inspection acceptance
• Support tooling design and fixture development to control alignment and distortion, ensuring dimensional accuracy, structural integrity, and repeatable weld quality across production hardware
• Troubleshoot weld defects, distortion, and variabilityt omaintainqualified welding processes and consistent production performance
• Provide daily support to tank fabrication and assembly operations, ensuring welding processes are executed correctly, issues are resolved in real time, and production progresses safely, efficiently, and to flight-quality standards

• Bachelor’s degree in Welding Engineering, Materials Science, Mechanical Engineering, or related field.(Required)
• 5+ years of experience developing and qualifying weld processes for aerospace or high-performance pressure vessels.(Required)
• Strong understanding of weld setup, joint design, fixturing, and distortion control.
• Strong understanding of weld metallurgy, defects, and NDE methods.
• Ability to work directly on the shop floor in a fast-paced startup environment.
• Experienceoperatingunder aggressive schedules with flight-critical hardware.

• Priorworkon launch vehicles, spacecraft, or flight pressure vessels.
• Experience workingtoAWS D17.1 and AIAA S-080 standards.
• Experience working in handheld laser and robotic laser weld cells.
• Experience with laser welding of thin-wall aerospace structures.
• Background working in startup orrapid-development environments.

The estimated salary range for this role reflects various compensation factors. The final offer depends on factors such as work experience, education, training, key skills, and business needs.

In addition, LEAP provides a comprehensive benefits package for full-time employees, which includes:

• Equity Program: Equity plan participation is available to all employees following an initial
  90-day employment period and is performance-based. Equity allocations aredeterminedon a case-by-case basis and are not guaranteed. Managers may make recommendations based on individual and team performance. All equity grants are subject to executive review and approvalin accordance withthe Company’s equity plan.
• Retirement Planning:Save for the future with a 401(k) plan that includes competitive company matching.
• Growth Opportunities:Take advantage of a professional development stipend to…