Research Engineer-Autonomous Design & Thermomechanical Modeling

ARCTOS Technology Solutions, LLC

Reach New Heights! ARCTOS Technology Solutions, LLC (ARCTOS) is a fast‑growing, technology‑oriented small business providing aerospace, defense, and digital solutions, with offices and work sites across the United States. We're looking for team‑oriented innovators eager to tackle interesting challenges, work on important problems, and receive great benefits and employee support.

ARCTOS is seeking a highly skilled and motivated Research Engineer to join our team supporting AFRL's Manufacturing Technology Division (AFRL/RXM). This role is focused on advancing the state‑of‑the‑art in autonomous design and thermomechanical modeling for aerospace systems and integrating these models with cutting‑edge additive manufacturing (AM) processes. The successful candidate will drive both fundamental and applied research, developing novel design and performance modeling frameworks that explicitly incorporate manufacturability constraints, specifically for AM technologies.

• Design for Additive Manufacturing (DfAM):
  • Research and develop methodologies for tailoring design and optimization frameworks (e.g., topology optimization, generative design) to account for AM process‑induced constraints, defects, and material anisotropy.
  • Integrate manufacturability metrics directly into the design loop to ensure optimized components are successfully produced using AM.
• Thermomechanical Modeling & Simulation:
  • Develop, implement, and validate advanced finite element analysis (FEA) and other numerical models, including machine learning frameworks, to predict the thermomechanical performance of materials and components under extreme operating conditions relevant to Air Force applications.
  • Focus on modeling the performance of systems where thermal loads and mechanical stresses are intrinsically coupled.
• Research Leadership and Execution:
  • Lead and contribute to applied and fundamental research projects, resulting in high‑impact publications, technical reports, and transition of technologies to Air Force programs.
  • Work effectively on multidisciplinary teams to tackle complex, interconnected engineering problems.
• Software and Tool Development:
  • Utilize and maintain proficiency in commercial engineering mechanics and design software (e.g., Abaqus, ANSYS, COMSOL, nTop).
  • Develop, customize, and apply custom engineering mechanics and design software/scripts (e.g., in Python, MATLAB, C++) to extend capabilities and integrate specialized models.

• The well‑qualified candidate will have expertise in many of these areas:
  • Common commercial simulation software and programming languages for custom tool development.
  • Hands‑on experience in tailoring and optimizing engineering design frameworks (e.g., optimization algorithms, surrogate modeling, machine learning).
  • Proven experience in thermomechanical modeling for design, performance prediction, and manufacturing process modeling.
  • Demonstrated experience with FEA and multi‑physics applications.
  • Experience with applying classic and modern machine learning algorithms to optimization and engineering problems, e.g. active learning (Bayesian optimization, reinforcement learning), deep learning (neural networks).
  • Specific experience with additive manufacturing processes (e.g., Powder Bed Fusion, Directed Energy Deposition) and understanding of how process parameters influence material properties and component performance.
• Excellent organizational and time management abilities.
• Desire to work both independently and in a team environment as the project requires.
• Excellent verbal and written communication skills.
• Proven track record in conducting both applied and fundamental research, evidenced by publications, patents, or successful technology demonstrations.

• M.S. or Ph.D. in Mechanical Engineering, Aerospace Engineering, Materials Science, or a closely related field.
• U.S. Citizenship is required.

• Primary work environment is a standard office setting.

• Occasional travel is expected and will be performed under the guidelines of Federal Travel Regulations (FTR)…