Composite Design Engineer

Role details

We are seeking an experienced Senior Composite Design Engineer to lead the design and development of advanced composite structures for aerospace applications. This role is responsible for creating innovative, lightweight, and high-strength composite components while ensuring compliance with customer specifications, FAA, DoD, and aerospace industry standards. The ideal candidate has extensive experience designing primary and secondary composite structures, performing engineering analyses, and supporting products throughout the development and manufacturing lifecycle.

Key Responsibilities

• Design and develop composite aerospace components and structural assemblies for commercial, military, and space applications.
• Create 3D CAD models, engineering drawings, and detailed manufacturing documentation using CATIA, Siemens NX, SolidWorks, or similar CAD software.
• Develop laminate schedules, ply books, stack-up definitions, and material specifications for composite structures.
• Perform structural design activities including weight optimization, manufacturability, and cost reduction initiatives.
• Work closely with stress analysts to validate designs through finite element analysis (FEA), static strength, fatigue, and damage tolerance assessments.
• Collaborate with manufacturing engineering to optimize tooling, layup methods, curing processes, and production workflows.
• Support prototype development, first article inspections (FAI), qualification testing, and certification efforts.
• Evaluate engineering change requests (ECRs), engineering change orders (ECOs), and implement design improvements.
• Review supplier drawings, material certifications, and manufacturing processes to ensure compliance with engineering requirements.
• Participate in design reviews including PDR, CDR, MRB, and customer technical meetings.
• Investigate production issues and provide root cause analysis and corrective actions related to composite structures.
• Ensure compliance with aerospace quality standards including AS9100, customer specifications, and regulatory requirements.
• Mentor junior engineers and provide technical leadership across cross-functional engineering teams.
• Support proposal development, technical presentations, and customer interactions when required.

Qualifications

• Bachelor's degree in Aerospace Engineering, Mechanical Engineering, Materials Engineering, or a related engineering discipline.
• Master's degree preferred.
• 8+ years of experience designing composite structures in the aerospace industry.
• Extensive knowledge of carbon fiber, fiberglass, honeycomb sandwich panels, prepreg systems, resin systems, and composite manufacturing processes.
• Strong understanding of composite mechanics, laminate theory, failure modes, and structural design principles.
• Experience designing primary and secondary aircraft structures.
• Proficiency with CATIA V5/V6, Siemens NX, SolidWorks, or similar 3D CAD software.
• Experience with FEA software such as ANSYS, Abaqus, NASTRAN, or HyperMesh is preferred.
• Familiarity with GD&T and engineering drawing standards.
• Experience with aerospace certification requirements and qualification testing.
• Knowledge of FAA regulations, military specifications, or customer-specific aerospace requirements.
• Strong understanding of Design for Manufacturability (DFM) and Design for Assembly (DFA).
• Excellent analytical, communication, and project management skills.

Preferred Qualifications

• Experience supporting defense or military aerospace programs.
• Knowledge of automated fiber placement (AFP) and automated tape laying (ATL) processes.
• Experience with composite repair design and structural substantiation.
• Familiarity with PLM systems such as Teamcenter or Windchill.
• Experience with requirements management and configuration control.
• Professional Engineer (PE) license is a plus.

Technical Skills

• Composite structural design
• Carbon fiber and advanced composite materials
• Laminate design and ply development
• CATIA V5/V6, Siemens NX, SolidWorks
• Finite Element Analysis (FEA)
• GD&T
• Engineering drawings
• AS9100 Quality Management System
• FAA and DoD compliance
• Root Cause Analysis
• Product lifecycle management (PLM)
• Design Reviews (PDR/CDR)
• DFM/DFA
• Manufacturing process development

Preferred Industry Experience

• Aerospace manufacturing
• Defense contractors
• Aircraft structures
• Space systems
• Unmanned aerial systems (UAS/UAV)
• Commercial aviation
• Rotorcraft
• Advanced composite manufacturing