Structural Design Engineer

Mechanical Design Engineer – Space and Air Vehicle Structures

This role focuses on mechanical design with a strong emphasis on doors, including hinge and latch mechanism design, within advanced space and air vehicle programs. The engineer will develop complex kinematic solutions in a conceptual design environment, lead and guide structural architecture for primary and secondary composite structures, and support the full product development lifecycle from concept through detailed design. The position requires extensive experience in space vehicle and aerospace structural design and offers the opportunity to mentor junior engineers while contributing to innovative, weight- and cost-optimized solutions.

Responsibilities

• Design mechanical systems with emphasis on doors, including hinge and latch mechanisms, ensuring robust, reliable, and maintainable solutions.
• Develop complex kinematic solutions in a conceptual design environment to support mechanisms and moving structures.
• Lead and guide structural architecture definition by identifying and proposing advanced technologies and materials.
• Provide technical guidance to junior engineers in structural and mechanical design, promoting best practices and design standards.
• Support design activities through trade studies, concept development, and interface development to optimize performance, weight, cost, and schedule.
• Create and refine composite primary and secondary structure designs using CATIA and related tools.
• Design structures using high-temperature materials and appropriate forming processes.
• Apply Geometric Dimensioning and Tolerancing (GD&T) to ensure clear, manufacturable engineering definitions.
• Develop and maintain CATIA part, assembly, surface, wireframe, and composite models in accordance with established design processes.
• Create, manage, and run Global Finite Element Models (GFEMs) that can be utilized by the broader stress team.
• Create and execute Detail Finite Element Models (DFEMs) to support detailed structural analysis and validation.
• Develop simple working finite element models for conceptual design work to validate design principles and support early trade studies.
• Execute design trade studies to evaluate multiple solutions and down select options that best meet weight, cost, and schedule constraints.
• Collaborate in an Integrated Product Team (IPT) environment with design, fabrication, assembly, and other key functions to ensure cohesive product development.
• Incorporate knowledge of various material forms and processes into conceptual design trade studies and structural solutions.
• Contribute to the design of aero structures and new product development, including wings, fuselage, vertical tail, and air vehicle doors when applicable.
• Ensure compliance with program design processes, configuration control, and documentation requirements throughout the project lifecycle.

Essential Skills

• Extensive experience in space vehicle design and aerospace structural design.
• Strong experience in mechanical design with emphasis on doors, including hinge and latch mechanism design.
• Proven ability to design complex kinematic solutions in a conceptual design environment.
• Hands-on experience with composite primary and secondary structure design.
• Experience with high-temperature material forming and associated design considerations.
• Proficiency in CATIA, including part design, assembly design, surface and wireframe modeling, and composite workbench.
• Experience using ENOVIA for product lifecycle and data management.
• Geometric Dimensioning and Tolerancing (GD&T) experience.
• Experience in creating, managing, and running Global Finite Element Models (GFEMs) for use by stress teams.
• Experience in creating and executing Detail Finite Element Models (DFEMs).
• Ability to create simple working finite element models for conceptual design validation.
• Knowledge of various material forms and manufacturing processes relevant to conceptual design trade studies.
• Experience executing design trade studies to evaluate and down select structural solutions based on weight, cost, and schedule.
• Ability to work effectively in an Integrated Product Team (IPT) environment with design, fabrication, and assembly functions.
• Bachelor's degree (minimum) in engineering; applicants with engineering degrees are strongly preferred over drafter or technical product designer backgrounds.
• Experience with composite design and aerospace structures, including primary structures.
• Recent commercial aerospace structures experience (within the last 10 years), preferably with fuselage or major structural components.
• Proficiency with established aerospace design processes and configuration management.

Additional Skills & Qualifications

• Experience in wing design, including primary and secondary structures.
• Experience in fuselage design, including frames, stringers, and clips.
• Experience in vertical tail design and related aero structures.
• Experience in air vehicle door design, including mechanisms and sealing interfaces.
• Background in aero structures,…