Structures Design Engineer- Staff/Senior

Structures Design Engineer- Staff/SeniorPosition OverviewAt 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:ResponsibilitiesTechnical 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 $164,000.00Maximum Range: $112,000.00 to $199,000.00