Does Firehawk Aerospace sponsor work visas for the Senior Structural Analysis Engineer - Composites role?

This role requires US citizenship — not just permanent residency.

Where is the Senior Structural Analysis Engineer - Composites role at Firehawk Aerospace based?

This role is based in Addison, TX.

How many years of experience does this Senior Structural Analysis Engineer - Composites role require?

The posting calls for at least 5 years of relevant experience.

What polymers or materials does this Senior Structural Analysis Engineer - Composites role work with?

carbon fiber, fiberglass, Kevlar, polymer composites.

What techniques or methods are required for this Senior Structural Analysis Engineer - Composites role?

finite element analysis, classical laminate theory, composite failure analysis.

One of 8,134 open polymer and materials roles on Crosslinked, each read for materials, degree, visa and salary. See roles like this

Senior Structural Analysis Engineer - Composites

Firehawk Aerospace · Addison, TXtoday

BS-level Process Engineering roles on Crosslinked list a median of $115k (780 that show pay). This posting does not list pay.

Perform FEA and laminate analysis of composite aerospace structures, define layups, and support composite fabrication and testing.

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Worth knowing

Why it is interesting. Bridges FEA and hands-on composite fabrication on rocket motor cases and pressure vessels

Might not be for you. Analysis-heavy structural role with FEA focus, not materials development or formulation

Mostly desk workDeep specialist Senior hires only Realistic requirements

Adjacent materials roleComposite structural analysis; layup schedules, ply stacking, material selection; carbon fiber/fiberglass/Kevlar; autoclave, filament winding, RTM; ASTM D3039 tests

Seniority: Senior
Work: On-site
Type: Full-time
Degree: BS
Experience: 5+ yrs
Industry: Aerospace
Role: Process Engineering
Schedule: Compressed 9/80
Clearance: Ability to obtain
Visa: US citizenship required

Materials

carbon fiber71 roles fiberglass116 roles Kevlar18 roles polymer composites29 roles high temperature composite systems1 role

Techniques

finite element analysis62 roles classical laminate theory4 rolescomposite failure analysisASTM D3039 tensile testingASTM D34101 role ASTM D55281 rolevibration and shock analysis

Benefits

100% employer-paid medical premiumsflexible 9/80 schedulementorship opportunities

Role details

About The Role

We are seeking a Structural Analysis Engineer with Composite background to join our engineering team. This role combines advanced structural analysis with hands-on knowledge of polymer composite manufacturing and design. The ideal candidate will bridge the gap between theoretical analysis and practical fabrication, ensuring our composite structures are optimized for both performance and manufacturability. Knowledge in high temperature composite material and having a dynamics analysis background is a plus.

Key Responsibilities

Perform structural analysis of composite components using finite element analysis (FEA) tools (ANSYS, Abaqus, NASTRAN, or similar)
Knowledge of classical laminate theory and composite hand calculation methods
Conduct stress analysis, failure prediction, and damage tolerance assessments for composite laminates and structures
Develop and validate composite layup schedules considering manufacturing constraints and structural requirements
Support design reviews with analysisdriven recommendations on fiber orientation, ply stacking sequences, and material selection
Collaborate with manufacturing teams to ensure designs are producible and address fabrication challenges
Perform trade studies comparing composite materials, processes, and configurations
Support testing programs including correlation of analytical models with test data
Generate technical reports, analysis documentation, and design justification packages
Support nonconformances during prototype, development and manufacturing trials
Interface with customers, suppliers, and crossfunctional teams on composite structural requirements

Required Qualifications

Bachelor's degree in Aerospace Engineering, Mechanical Engineering, or related field
5+ years of experience in composite structural analysis
Proficiency with FEA software (ANSYS, Abaqus, NASTRAN, or equivalent)
Working knowledge of composite materials (carbon fiber, fiberglass, Kevlar) and manufacturing processes (hand layup, autoclave cure, filament winding, RTM)
Understanding of composite failure theories (TsaiWu, TsaiHill, Hashin, etc.)
Experience with composite design principles and laminate theory
Strong analytical and problemsolving skills
Excellent written and verbal communication abilities

Preferred Qualifications

Master's degree in relevant engineering discipline
10+ years of experience in composite structural analysis
Handson experience with composite fabrication or manufacturing engineering
Knowledge of aerospace or defense industry standards (MILHDBK17, NCAMP, CMH17)
Experience with composite design software (HyperSizer, ESAComp, Fibersim, or similar)
Familiarity with test methods (ASTM D3039, D3410, D5528, etc.)
Background in rocket motor cases, pressure vessels, or aerospace structures
Knowledge in high temperature composite material systems
Programming/scripting skills (Python, MATLAB) for analysis automation
Experience in mechanical dynamics, vibration analysis, shock response, and environmental loading principles.
Active security clearance or ability to obtain one

ITAR Requirements

To conform to U.S. Government space technology export regulations, including the International Traffic in Arms Regulations (ITAR), you must be a U.S. citizen, lawful permanent resident of the U.S., a protected individual as defined by 8 U.S.C. 1324b(a)(3), or eligible to obtain the required authorizations from the U.S. Department of State.

Work Environment and Physical Requirements

This position requires mobility across manufacturing, testing, machine shop, and outdoor test environments. Duties may include walking, climbing, lifting up to 25 pounds, and working in high-hazard areas with appropriate PPE. Personal protective equipment such as safety glasses, safety shoes, hearing protection, flame-resistant clothing, and respiratory protection may be required based on task demands. The role may involve varying work hours including early mornings, nights, or weekends to support operations or facility maintenance activities.

Security Clearance

May be required to obtain and maintain a U.S. Security Clearance at the appropriate level. Requires U.S. Citizenship and ability to meet federal requirements for access to sensitive information.

Benefits at Firehawk Aerospace

100% employerpaid medical premiums for employees and up to 75% for dependents on select plans
Affordable dental and vision plans with extensive coverage
Employee Assistance Program including counseling, legal services, and wellness resources
Flexible 9/80 work schedule option
Onsite snacks and refreshments
Mentorship opportunities and involvement in advanced aerospace projects

Firehawk Aerospace is an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to protected characteristics.