Research Engineer - Composite Modeling

Role details

DCS is seeking a highly motivated research scientist or engineer to join our team supporting the AFRL/RE Composite, Ceramic, Metallic & Materials Performance Division. This position will lead efforts to fill critical gaps in the understanding of the behavior of ceramic matrix composites and translate that knowledge into models to predict performance and durability in extreme hypersonic and space operational environments.

The successful candidate will operate at the intersection of experimental mechanics, advanced diagnostics, and multiscale computational modeling. Working alongside materials development, processing, and characterization scientists, this individual will spearhead the development of novel testing frameworks and non-traditional modeling paradigms that overcome the limitations of legacy methods.

Essential Job Functions

The Research Engineer will collaborate with Government sponsors, research partners, and multi-disciplinary technical teams in the performance of the following duties:

Formulate and implement advanced computational modeling strategies that move beyond classical continuum homogenization to account for thin-ply features, architectural complexity, and lack of length-scale separation.

Develop and execute or guide novel mechanical testing methodologies tailored to complex CMC architectures, moving beyond legacy standards derived from metals and traditional polymer composites.

Correlate high-resolution material characterization data (e.g., X-ray computed tomography, microstructural quantification) directly with finite element models and failure predictions.

Establish progressive design and life-prediction methodologies that replace overly conservative, empirical knockdowns with physics-based, risk-quantified design margins.

Collaborate with materials processing teams to assess how emerging manufacturing pathways influence defect distributions, geometric variation, and component structural integrity.

Present findings at technical conferences, author technical reports and peer-reviewed publications, and brief senior stakeholders on technical progress and strategic impact.

Required Skills

Due to the sensitivity of customer related requirements, U.S. Citizenship is required.

Able to obtain and maintain a U.S. Department of War Secret security clearance.

M.S. or Ph.D. in Materials Science and Engineering, Mechanical Engineering, Aerospace Engineering, Engineering Mechanics, or a related technical field.

4 years of experience supporting engineering analysis, scientific computing, digital engineering, experimental thermomechanical testing, or computational mechanics is highly desirable.

Experience supporting DoW, aerospace, or other configuration-controlled engineering programs is highly desirable.

The well-qualified candidate will have expertise in several of the following areas:

Computational Modeling & Mechanics of Materials

Solid foundation in continuum mechanics, fracture mechanics, and damage mechanics.

Experience developing finite element analysis (FEA) models for heterogeneous or architected materials using commercial solvers (Abaqus, ANSYS, COMSOL) or research codes.

Expertise in mesoscale modeling, discrete-damage modeling, or multiscale mechanics.

Scripting and scientific computing proficiency (Python, MATLAB, C++, or Fortran) for automated model generation, data reduction, and scientific visualization.

Mechanical Testing & Advanced Characterization

Hands-on experience developing and/or executing thermomechanical material tests for extreme environments (thermal gradients, complex multiaxial stress states), preferably for ceramics or CMCs.

Expertise in full-field strain measurement techniques (2D/3D DIC).

In-depth understanding of non-destructive evaluation (NDE) and advanced characterization methods (e.g., micro-CT, synchrotron X-ray imaging, SEM/EDS, acoustic emission).

Design Methodologies & Systems Context

Familiarity with hypersonic thermal protection systems (TPS) or hot-structure concepts.

Appreciation for uncertainty quantification (UQ), sensitivity analysis, and probabilistic design frameworks.

Understanding of how component geometry, manufacturing defects, and processing variability influence structural performance and certification.

Desired Skills

The successful candidate should be:

An agile, interdisciplinary thinker able to bridge the gap between hands-on laboratory experimentation and advanced computational mechanics.

Enthusiastic in tackling unconventional problems that lack established textbook solutions.

A strong communicator capable of articulating complex physical phenomena clearly to experimentalists, computational modelers, and program leadership.

Self-motivated and comfortable driving research projects forward in collaborative, rapidly evolving R&D environments.