Lead, Structural Engineering

Lead, Structural Engineer

Join our team shaping the next generation of solid rocket propulsion systems. We are seeking a Lead, Structures & Dynamics stress analyst for our Huntsville AL or Sacramento, CA location. In this role, you will perform structural analysis to verify product designs meet structural performance requirements and assist with preliminary design verification.

As a key contributor, you will support structural modeling and analysis efforts for solid rocket motor (SRM) components throughout the product lifecycle—from early development through qualification and production. You will collaborate closely with cross-disciplinary teams, interface with customers, and drive technical excellence.

Essential Functions:

• Structural Analysis Ownership:
  Drive analysis tasks for SRM components including metallic and composite motor cases, nozzles, insulation, and propellant grains. Ensure structural integrity across all phases of flight and ground handling.
• FEA Modeling & Execution:
  Build and execute finite element models using ANSYS, ABAQUS, or comparable tools. Model components using isotropic, orthotropic, and viscoelastic material definitions with nonlinear and temperature-dependent properties. Apply classical methods to validate and supplement numerical results, especially for preliminary design trades or quick-turn assessments.
• Margin of Safety Evaluation:
  Determine margins of safety against yield, ultimate failure, buckling, HCF, LCF, and fracture using established industry standard practices and internal allowables. Produce high-quality technical reports, stress notes, and presentations that clearly outline methods, assumptions, and conclusions for both internal reviews and external customer delivery.
• Design Integration:
  Participate in formal and informal design reviews. Communicate results, trade-offs, and risk areas effectively to multidisciplinary audiences, including program management and external customers.
• Process Improvement:
  Contribute to internal tool development, analysis automation, and knowledge capture to enhance team efficiency and standardization.
• Ability to obtain a US Secret Security Clearance.
• Travel: 10%

Qualifications:

• Bachelor's Degree and minimum 9 years of prior structural analysis experience. Graduate Degree and a minimum of 7 years of prior structural analysis experience. In lieu of a degree, minimum of 13 years of prior structural analysis experience.

Preferred Additional

Skills:

• Bachelor's Degree (in Mechanical, Aerospace, or related Engineering discipline) is preferred.
• Proven experience in linear, nonlinear, and dynamic structural analysis supporting design and qualification of solid rocket motors.
• Proficiency with FEA tools such as ANSYS Mechanical; experience with ANSYS MAPDL or Python scripting is highly desirable.
• Familiarity with structural assessment and design of filament-wound composite pressure vessels is a strong asset.
• Demonstrated ability to interpret aerospace structural requirements and coordinate load development with cross-functional teams.
• Exposure to full lifecycle aerospace SRM propulsion product development, from design through manufacturing and test.