Structures Design Engineer- Staff/Senior

Structures Design Engineer- Staff/Senior

Position Overview

At Aurora Flight Sciences, we design, build, and fly advanced aircraft and enabling technologies from concept to reality. We are searching for a talented and self-motivated Structures Design Engineer- Staff/Senior to help us create the future of flight. Responsibilities will include but not be limited to the following:

Responsibilities

Technical Leadership:

• Provide the first line of technical authority within the design team, with responsibility for approving design concepts and determining technical objectives for projects.
• Lead by example, mentoring and guiding junior engineers while working independently for extended periods.

Design and Development:

• Create airframe structural configuration layouts and detailed designs, including preliminary sizing, joint layouts, and interface boundary definitions for parts and assemblies, working with both metallic and composite materials.
• Develop and maintain CAD models and drawings of installations, assemblies, and detail components, ensuring strict adherence to structural integrity, interface boundaries, weight, and cost targets.
• Conduct design reviews and validate product structures to ensure components meet functional, fit, and form requirements.

Project Execution:

• Assume ownership of project execution and integration, leading teams of engineers to deliver against program budgets and deadlines.
• Coordinate with stress, manufacturing, procurement, and quality control teams to mature designs from initial conception to full-scale production.
• Track weekly progress and maintain project documentation to ensure alignment with program milestones.

Cross-Functional Collaboration:

• Collaborate effectively with manufacturing and tooling teams for prototyping, material selection, and production strategies, particularly for composite components.
• Prepare and present technical and programmatic data during Preliminary Design Reviews (PDRs) and Critical Design Reviews (CDRs).

Mentorship and Training:

• Offer technical guidance and mentorship to team members, including junior designers, to achieve high-quality deliverables.

Minimum Requirements

• Ability to obtain a US Security Clearance for which the US Government requires US Citizenship.
• Bachelor's Degree in Mechanical Engineering, Aerospace Engineering, or a related discipline.
• Minimum of 5 years of experience in aerospace or related fields.
• Competence with CAD software, particularly CATIA V5, SmarTeam, or similar product data management systems (e.g., Enovia LCA or PDM).
• Knowledge of industry standards relating to composite component design, manufacturing, repair, and assembly (specific to aerospace).
• Proficiency with Microsoft Office 365 (Excel, Word, and PowerPoint).
• Strong verbal and written communication skills with a collaborative mindset.

Preferred Requirements

• Expertise in CATIA V5 modules, including Generative Surface Design, Part Design, and Assembly (experience with Unigraphics or Siemens NX will be considered).
• Advanced knowledge of composite material structures, including design, stacking sequences, lamination theory, bonded assemblies, and post-cure machining operations.
• Familiarity with prototype and rate production, including exposure to manufacturing tooling design, planning, and hands-on fabrication.
• Geometric Dimensioning and Tolerancing (GD&T): Knowledge of ASME Y14.5 and related tolerance analysis techniques.
• Experience with Model-Based Definition (MBD): Familiarity with ASME Y14.41 methods and CATIA V5 FTA for functional tolerancing and annotations.
• Strong foundation in manufacturing and development of aerospace structural components and assemblies.

Physical Requirements

• Ability to work on-site on a weekly basis at our Manassas, VA or Cambridge, MA locations.

Salary Range (Annualized USD)

• Minimum Range: $92,000.00 to $164,000.00
• Maximum Range: $112,000.00 to $199,000.00