Aerospace Senior Design Lead

Overview

Expleo Group USA is seeking experienced Aerospace Senior Design Leads to support current aerospace programs focused on aircraft design, reverse engineering, product development, manufacturing support, and configuration management in Washington State
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• Lead reverse engineering activities utilizing 3D scanning technology and digital inspection tools.
• Develop accurate CAD models and engineering documentation from scanned parts and legacy components.
• Create, modify, and maintain detailed engineering drawings and 3D models using Solid Works.
• Define and validate critical dimensions, tolerances, and key product characteristics.
• Support design improvements, configuration changes, and modification efforts across aircraft platforms.
• Analyze existing components and assemblies to develop production-ready engineering documentation.

• Lead design activities from concept through release and implementation.
• Generate detailed engineering drawings, models, assemblies, and manufacturing documentation.
• Ensure designs comply with aerospace standards, quality requirements, and manufacturing capabilities.
• Support root cause investigations and corrective actions related to design and manufacturing issues.
• Collaborate with cross-functional teams supporting prototype development, production, and sustainment efforts.
• Evaluate design alternatives to improve manufacturability, quality, and performance.

• Manage engineering data within Product Data Management (PDM) systems.
• Maintain revision control and ensure proper release of engineering documentation.
• Support Engineering Change Requests (ECRs) and Engineering Change Orders (ECOs).
• Ensure configuration traceability and compliance with customer and regulatory requirements.
• Maintain accurate documentation and drawing revision histories.

• Provide engineering support to production, tooling, and quality teams.
• Interface with CNC programmers, manufacturing engineers, and technicians to ensure designs are manufacturable.
• Review manufacturing processes and recommend design improvements to enhance quality, efficiency, and cost performance.
• Support inspection planning and validation activities utilizing GD&T requirements.
• Assist with troubleshooting production and assembly challenges.

• Serve as the technical lead for assigned projects and engineering initiatives.
• Mentor junior engineers, designers, and technicians.
• Participate in design reviews, manufacturing reviews, and customer technical discussions.
• Coordinate with Airbus, suppliers, and internal stakeholders to achieve project objectives.
• Support strategic product improvement and engineering standardization initiatives.

• Bachelor's Degree in Mechanical Engineering, Aerospace Engineering, Manufacturing Engineering, or a related technical discipline.
• Equivalent combination of education and significant aerospace design experience may be considered.
• 10+ years of aerospace design, manufacturing, product development, or related engineering experience.
• Experience supporting aircraft structures, aerospace components, or aerospace manufacturing environments.
• Experience leading technical projects and working within multidisciplinary engineering teams.
• Strong proficiency in Solid Works for part, assembly, and drawing creation.
• Experience with 3D scanning technologies and reverse engineering methodologies.
• Advanced knowledge of GD&T (Geometric Dimensioning & Tolerancing) and tolerance stack-up analysis.
• Experience creating and interpreting aerospace engineering drawings.
• Strong understanding of Product Data Management (PDM) systems and revision control processes.
• Wor…