UAS Composites Engineer

Title: UAS Composites Engineer

Company: Heven Aero Tech

Location: Sterling, Virginia

FLSA: Exempt

We are seeking a highly skilled UAS Engineer with a focus on composite structures and payload integration to support the design, development, and deployment of advanced unmanned aerial systems (UAS). This role bridges airframe engineering and mission capability, ensuring that composite structures and payload systems are efficiently integrated, structurally sound, and optimized for performance.

The ideal candidate combines hands‑on experience with composite materials, strong systems‑level thinking, and a design‑for‑manufacturing mindset to integrate sensors, electronics, and mission‑specific payloads into robust, flight‑ready platforms.

• Design, analyze, and optimize highly manufacturable composite airframe structures (fuselage, wings, mounts, enclosures), applying Design for Manufacturing principles to ensure scalable and reliable production.
• Select appropriate composite materials (carbon fiber, fiberglass, resins, cores) based on performance, weight, reliability, and manufacturability trade‑offs.
• Develop CAD models, drawings, and documentation for composite components using tools such as Solid Works, CATIA, or NX.
• Perform structural analysis (FEA, hand calculations) to validate strength, stiffness, durability, and performance margins with attention to detail and analytical rigor.
• Support fabrication processes including layup, curing, trimming, and finishing with a focus on repeatable, high‑quality manufacturing outcomes.
• Lead integration of payload systems including sensors, cameras, communication modules, and mission‑specific equipment, ensuring cross‑disciplinary collaboration across mechanical, electrical, and software teams.
• Define mechanical, electrical, and thermal interfaces between payloads and airframe, ensuring robust integration and system reliability.
• Design mounting solutions that ensure stability, vibration isolation, serviceability, and operational durability.
• Manage payload weight, balance, and power constraints while applying systems thinking to evaluate impacts on flight performance, CG, endurance, and structural loads.
• Conduct trade studies to balance payload capability with range, endurance, and overall mission performance.
• Support system architecture development and configuration control across evolving UAS platforms.
• Plan and execute ground and flight tests for structural and payload validation, leveraging test data to iterate and improve designs.
• Troubleshoot integration issues in fast‑paced development cycles and implement effective corrective actions.
• Develop and document repeatable manufacturing processes for composite components in collaboration with suppliers and internal teams.
• Support transition from prototype to low‑rate and full‑rate production environments.

• 7+ years of experience in UAS, aerospace, or related industries.
• Strong experience with composite materials and fabrication methods.
• Proficiency in CAD tools (Solid Works, CATIA, NX, or equivalent).
• Experience with payload integration at the mechanical and/or systems level.
• Understanding of structural analysis and basic FEA tools.
• Familiarity with UAS platforms, flight dynamics, and system‑level constraints.
• Strong problem‑solving and analytical skills with a focus on reliability and performance.
• Ability to work effectively in fast‑paced, iterative engineering environments.
• Strong communication skills and ability to collaborate across engineering disciplines.

• Bachelor’s or Master’s degree in Aerospace Engineering, Mechanical Engineering, or related field.
• Experience with small to medium UAS platforms.
• Knowledge of vibration isolation and thermal management for payload systems.
• Hands‑on experience with composite layup and rapid prototyping.
• Familiarity with avionics, sensors, and communication systems.
• Experience with 3D printing, CNC machining, and tooling design.
• Understanding of regulatory considerations (FAA, MIL standards, etc.).

Heven Aero Tech offers a competitive benefits package designed to support the health, financial security, and overall well‑being of our employees and their families. Benefits include medical, dental, and vision coverage, retirement plans, paid time off/sick, and additional protections such as critical illness, hospital indemnity, accident coverage, and short‑ and long‑term disability.

Heven Aero Tech is an Equal Opportunity Employer and considers all qualified applicants without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, disability, veteran status, or any other protected characteristic under applicable law.

Salary Range: $70,000 USD - $150,000 USD