Aero-Structural Design and Manufacturing Engineer

Role details

Aero-Structural Design and Manufacturing Engineer

The Opportunity

As an Aero-Structural Design and Manufacturing Engineer, you know leading-edge design and high-quality materials and manufacturing are critical elements required in verifying aero-vehicle structural integrity throughout the product lifecycle. At Booz Allen, you can use your engineering expertise to develop next-generation defense tools and technology. We need your skills and expertise in the design of metallic and composite aircraft components, coupons, and related tooling and test fixtures to support stress analysis and load prediction, structural life forecasting, and structural integrity analysis for new and innovative aerospace solutions that directly impact the warfighter.

As an engineer working on our prototype design team, you’ll provide expertise in evaluating new technologies, performing risk assessments, and improving the design of aerospace systems. Your experience in aero-vehicle design is key and makes you an integral part of delivering a client-focused solution.

In this role, you’ll contribute to the direction of mission-critical solutions, working in a team environment alongside structural analysists, material science engineers, test engineers, machinists, and various researchers. If you desire to solve real-world challenges and lead mission-critical aerospace design engineering, there’s a place for you here. At Booz Allen, you’ll make a difference with us, and in return, we’ll invest in your future.

Join us. The world can’t wait.

You Have

• Experience with design, analysis, or fabrication in the aerospace industry
• Experience using design software, including AutoCAD, UG, SolidWorks, CATIA, or Pro-Engineer
• Experience using finite element methods and software tools, including ABAQUS, ANSYS, NASTRAN, PATRAN, or MATLAB
• Knowledge of metallic and composite structural design, analysis, and fabrication
• Knowledge of composite fabrication, assembly, and testing
• Knowledge of manufacturing and design techniques, procedures, and practices
• Knowledge of basic machine shop equipment, drill presses, grinders, band saws, shears, hand layout tools, and machine shop tools and practices
• Ability to work in and around large irregular shaped parts
• Ability to obtain a Secret clearance
• Bachelor's degree in Mechanical Engineering or Aerospace Engineering

Nice If You Have

• Experience using probabilistic composite structure stress, buckling and vibrational analysis methods, and hand calculations of Rourk and Bruhn
• Experience with aircraft structural layout and sizing, and aero-structural design using composite materials
• Experience with design for manufacturing techniques and procedures
• Experience with design and analysis of carbon fiber reinforced polymers, glass fiber reinforced plastics, discontinuous fiber composites, or ceramic matrix and high temperature composites
• Knowledge of composite-related nondestructive inspection, procedures, practices, and test processes in engineering
• Secret clearance
• Master's degree in Mechanical Engineering or Aerospace Engineering
• Military Aircraft Structural Integrity Programs (ASIP) Certification

Clearance

Applicants selected will be subject to a security investigation and may need to meet eligibility requirements for access to classified information.

Compensation

At Booz Allen, we celebrate your contributions, provide you with opportunities and choices, and support your total well-being. Our offerings include health, life, disability, financial, and retirement benefits, as well as paid leave, professional development, tuition assistance, work-life programs, and dependent care. Our recognition awards program acknowledges employees for exceptional performance and superior demonstration of our values. Full-time and part-time employees working at least 20 hours a week on a regular basis are eligible to participate in Booz Allen’s benefit programs.

Individuals that do not meet the threshold are only eligible for select offerings, not inclusive of health benefits. We encourage you to learn more about our total benefits by visiting the Resource page on our Careers site and reviewing Our Employee Benefits page.

Salary at Booz Allen is determined by various factors, including but not limited to location, the individual’s particular combination of education, knowledge, skills, competencies, and experience, as well as contract-specific affordability and organizational requirements. The projected compensation range for this position is $69,300.00 to $158,000.00 (annualized USD). The estimate displayed represents the typical salary range for this position and is just one component of Booz Allen’s total compensation package for employees. This posting will close within 90 days from the Posting Date.

Identity Statement

As part of the hiring process, we will ask you to complete an identity verification process that leverages advanced biometrics and artificial intelligence to ensure authenticity and protect against identity fraud. You are expected to be on camera during interviews and assessments. We reserve the right to take your picture to verify your identity and prevent fraud.

Candidate AI Usage Policy

AI is a part of our daily work at Booz Allen, and we are committed to the responsible and ethical use of AI tools. However, we want to ensure a fair candidate process based on your own skills and knowledge. As part of this commitment, the use of artificial intelligence (AI) or other tools to assist with responses during interviews (whether in-person or virtual) is prohibited unless permission is explicitly provided.

Work Model

Our people-first culture prioritizes the benefits of collaboration. To support engagement and effective communication, employees working virtually are generally expected to have their cameras on during meetings.

• Remote: If this position is listed as remote, there may still be occasions when you are required to work in person at a Booz Allen or customer facility.
• Hybrid: If this position is listed as hybrid, you will be expected to work from a Booz Allen or customer facility, in alignment with your leadership's expectations and the needs of the role.
• Onsite: If this position is listed as onsite, work will primarily be performed full-time at a customer facility, where employees will collaborate directly with colleagues and customers as required by the role.

Commitment to Non-Discrimination

All qualified applicants will receive consideration for employment without regard to disability, status as a protected veteran or any other status protected by applicable federal, state, local, or international law.