Aerospace Senior Design Lead

Expleo; Washington (District of Columbia); On-site; USD 120,000 - 200,000; Full time

Benefits offered by this job

Competitive pay and benefits

Paid holidays and PTO

Career development

Strong team culture

Job summary

Expleo Group USA seeks Aerospace Senior Design Leads to support current programs focused on aircraft design, reverse engineering, product development, manufacturing support and configuration management in Washington State.

Lead reverse engineering with 3D scanning, develop CAD models and drawings in SolidWorks, manage PDM/revision control, and collaborate with Airbus suppliers and cross-functional teams to improve manufacturability, quality and performance.

Qualifications

• Bachelor's Degree in Mechanical Engineering, Aerospace Engineering, Manufacturing Engineering, or related discipline.
• 10+ years aerospace design, manufacturing, product development, or related engineering experience.
• Experience leading technical projects in multidisciplinary engineering teams.
• Strong proficiency in SolidWorks for part, assembly, and drawing creation.
• Experience with 3D scanning technologies and reverse engineering methodologies.
• Advanced knowledge of GD&T and tolerance stack-up analysis.

Responsibilities

• Lead reverse engineering activities utilizing 3D scanning technology and digital inspection tools.
• Develop accurate CAD models and engineering documentation from scanned parts and legacy components.
• Create, modify, and maintain detailed engineering drawings and 3D models using SolidWorks.
• Define and validate critical dimensions, tolerances, and key product characteristics.
• Support design improvements, configuration changes, and modification efforts across aircraft platforms.
• Collaborate with cross-functional teams supporting prototype development, production, and sustainment efforts.

Skills

SolidWorks

3D scanning

GD&T

PDM

Revision control

CNC programming

UAS/UAV experience

Airbus programs

Education

Bachelor's degree in Mechanical Engineering

Tools

SolidWorks

3D scanning technologies

Job description

Overview

Expleo Group USA is seeking experienced Aerospace Senior Design Leads to support current aerospace programs focused on aircraft design, reverse engineering, product development, manufacturing support, and configuration management in Washington State.

Responsibilities:

Design Engineering & Reverse Engineering

• Lead reverse engineering activities utilizing 3D scanning technology and digital inspection tools.
• Develop accurate CAD models and engineering documentation from scanned parts and legacy components.
• Create, modify, and maintain detailed engineering drawings and 3D models using SolidWorks.
• Define and validate critical dimensions, tolerances, and key product characteristics.
• Support design improvements, configuration changes, and modification efforts across aircraft platforms.
• Analyze existing components and assemblies to develop production-ready engineering documentation.

Product Design & Development

• Lead design activities from concept through release and implementation.
• Generate detailed engineering drawings, models, assemblies, and manufacturing documentation.
• Ensure designs comply with aerospace standards, quality requirements, and manufacturing capabilities.
• Support root cause investigations and corrective actions related to design and manufacturing issues.
• Collaborate with cross-functional teams supporting prototype development, production, and sustainment efforts.
• Evaluate design alternatives to improve manufacturability, quality, and performance.

Configuration Management & Revision Control

• Manage engineering data within Product Data Management (PDM) systems.
• Maintain revision control and ensure proper release of engineering documentation.
• Support Engineering Change Requests (ECRs) and Engineering Change Orders (ECOs).
• Ensure configuration traceability and compliance with customer and regulatory requirements.
• Maintain accurate documentation and drawing revision histories.

Manufacturing Support

• Provide engineering support to production, tooling, and quality teams.
• Interface with CNC programmers, manufacturing engineers, and technicians to ensure designs are manufacturable.
• Review manufacturing processes and recommend design improvements to enhance quality, efficiency, and cost performance.
• Support inspection planning and validation activities utilizing GD&T requirements.
• Assist with troubleshooting production and assembly challenges.

Technical Leadership & Collaboration

• Serve as the technical lead for assigned projects and engineering initiatives.
• Mentor junior engineers, designers, and technicians.
• Participate in design reviews, manufacturing reviews, and customer technical discussions.
• Coordinate with Airbus, suppliers, and internal stakeholders to achieve project objectives.
• Support strategic product improvement and engineering standardization initiatives.

Qualifications:

• Bachelor's Degree in Mechanical Engineering, Aerospace Engineering, Manufacturing Engineering, or a related technical discipline.
• Equivalent combination of education and significant aerospace design experience may be considered.
• 10+ years of aerospace design, manufacturing, product development, or related engineering experience.
• Experience supporting aircraft structures, aerospace components, or aerospace manufacturing environments.
• Experience leading technical projects and working within multidisciplinary engineering teams.
• Strong proficiency in SolidWorks for part, assembly, and drawing creation.
• Experience with 3D scanning technologies and reverse engineering methodologies.
• Advanced knowledge of GD&T (Geometric Dimensioning & Tolerancing) and tolerance stack-up analysis.
• Experience creating and interpreting aerospace engineering drawings.
• Strong understanding of Product Data Management (PDM) systems and revision control processes.
• Working knowledge of configuration management practices.
• Ability to support manufacturing, tooling, and production engineering activities.
• Composite structures and aerospace manufacturing processes.
• Aluminum aircraft structures and fabrication methods.
• CNC machining and manufacturing processes.
• Tooling and fixture design concepts.
• Aerospace quality inspection methodologies.
• Aerospace production and assembly environments.
• Experience supporting Airbus programs.
• Experience supporting Unmanned Aircraft Systems (UAS) or UAV platforms.
• Hands-on CNC programming experience.
• Experience operating or supporting engineering scanning equipment.
• Knowledge of AS9100 quality standards.
• Familiarity with Airbus engineering processes and documentation requirements.
• Experience supporting prototype, low-rate production, or sustainment programs.

What We Offer

At Expleo Group USA, we value expertise, innovation, and collaboration. By joining our client's team, you'll work on cutting-edge aerospace programs while enjoying a supportive and technically engaging work environment.

• Competitive Compensation – Up to $200,000 annually or $97/hourly. Final compensation will be determined based on the role, skill alignment, years of experience, and fair, market-based rates by geography.
• Comprehensive Benefits for you and your dependents – Extensive Medical Plans, Dental, Vision, HSA with company contribution, company-sponsored Life Insurance and Short/Long-Term Disability Insurance, a host of voluntary plans including legal, hospital, accident, pet wellness, and 401(k) with matching.
• Paid Holidays and Paid Time Off
• Career Development and Advancement – Expleo is a global company operating in 29 countries with a strong focus on professional development.
• Strong Team Culture – Collaborate with experienced professionals who value technical excellence, innovation, and teamwork.

This position may require access to information subject to U.S. export control regulations (e.g., ITAR/EAR). Employment is contingent upon the ability to obtain such access. Under these regulations, access may be limited to "U.S. Persons," including U.S. citizens, lawful permanent residents (green card holders), and individuals granted refugee or asylee status.

Expleo is a trusted partner for end-to-end, integrated engineering, quality services, and management consulting for digital transformation. We are a talent incubator. The time you spend at Expleo will turbocharge your career, allowing you to work on complex technical challenges, expand your skills, and participate in inspiring multidisciplinary collaborations. Whether working on green aircraft, the factories of tomorrow, or cutting-edge digital engineering solutions, you'll have the opportunity to become a bolder version of yourself. Let's change the game together.

Expleo is an equal opportunity employer. We are committed to non-discrimination in all stages of the recruitment process, ensuring fair and unbiased hiring practices. We evaluate qualified applicants without regard to race, color, religion, sex (including pregnancy), sexual orientation, gender identity, national origin, age, disability, genetic information, or any other protected characteristic under applicable laws.