Composite Design Engineer

Sacbar; Santa Ana, Northern (CA, KY); Hybrid; USD 120,000 - 180,000; Full time

Job summary

All American Racers in Santa Ana, CA, seeks a Sr. Composite Design Engineer to lead complex design efforts, optimize structures, and ensure manufacturability and certifiability in aerospace programs.

You will create and review 3D models using CATIA/NX/SolidWorks, develop laminate schedules, and collaborate with stress, manufacturing, and quality teams to drive DFM and production readiness. Role requires extensive experience in composite structural design, CAD/FEA proficiency, and strong

Qualifications

• Bachelor’s degree in aerospace or related field; Master’s preferred.
• 10+ years in a similar role within the aerospace industry.
• Experience leading composite structural design and certification processes.

Responsibilities

• Lead the design and development of composite structures, ensuring performance, weight, cost, and manufacturability.
• Create and review 3D models, detailed drawings, and release packages using CATIA/NX/SolidWorks.
• Develop laminate schedules and ply books aligned with load cases and manufacturing constraints.
• Perform structural analysis with stress engineering to validate strength, stiffness, fatigue, and damage tolerance.
• Coordinate with manufacturing, tooling, quality, and supply chain for DFM and production transitions.
• Support prototype builds, FAI, and ramp activities; resolve technical issues as they arise.
• Participate in material and process selection (autoclave, OOA, RTM) and design trade studies.
• Generate and maintain specifications, reports, change notices, and configuration records.
• Support customer technical reviews, design audits, and certification activities.
• Drive continuous improvement in design standards, modeling practices, and processes.

Education

Bachelor’s degree in Aerospace Engineering / Mechanical Engineering / Materials Science

Master’s degree preferred

Tools

CATIA

NX

SolidWorks

Job description

POSITION SUMMARY:

The Sr. Composite Design Engineer will be responsible for leading complex design efforts, driving structural optimization, and ensuring designs are manufacturable, certifiable, and aligned with program requirements. The Sr. Composite Design Engineer will serve as a key technical contributor, collaborating cross-functionally to bring high-performance composite components from concept through production.

ESSENTIAL DUTIES AND RESPONSIBILITIES:

Lead the design and development of composite structures and components, ensuring compliance with aerospace performance, weight, cost, and manufacturability requirements.

Create and review 3D models, detailed drawings, and engineering release packages using CAD software (e.g., CATIA, NX, SolidWorks).

Develop laminate schedules, ply books, and composite stack-ups aligned with structural load cases and manufacturing constraints.

Perform structural analysis in collaboration with stress engineering to validate strength, stiffness, fatigue, and damage tolerance requirements.

Interface closely with manufacturing, tooling, quality, and supply chain teams to ensure design-for-manufacturability (DFM) and smooth transition into production.

Support prototype builds, first article inspections (FAI), and production ramp activities, resolving technical issues as they arise.

Participate in material selection, process selection (autoclave, OOA, RTM, etc.), and design trade studies.

Generate and maintain engineering documentation including specifications, reports, change notices, and configuration management records.

Support customer technical reviews, design audits, and certification activities.

Drive continuous improvement in composite design standards, modeling practices, and engineering processes.

POSITION QUALIFICATIONS:

Extensive experience in composite structural design within the aerospace industry.

Strong proficiency in CAD modeling, FEA, and drafting tools (CATIA, NX, SolidWorks, or equivalent).

Deep understanding of composite materials, laminate theory, ply orientation strategy, and aerospace structural requirements.

Familiarity with aerospace regulatory standards and quality systems (e.g., AS9100).

Experience working closely with manufacturing teams in a production environment.

Strong analytical thinking and problem-solving skills.

COMPETENCIES:

Technical Expertise: Advanced knowledge of composite structural design, laminate development, aerospace materials, and certification requirements.

Engineering Judgment: Demonstrates strong decision-making capability in evaluating design trade-offs, structural performance, and manufacturability.

Problem Solving: Proactively identifies design risks and implements technically sound, data-driven solutions.

Collaboration: Works effectively with cross-functional teams including stress, manufacturing, quality, and program management to achieve program milestones.

Continuous Improvement: Actively improves design methodologies, modeling standards, and engineering efficiency.

Communication: Clearly articulates complex technical concepts to internal teams, leadership, and customers.

EDUCATION / EXPERIENCE:

Education: Bachelor’s degree in Aerospace Engineering, Mechanical Engineering, Materials Science, or related field required; Master’s degree preferred.

Experience: 10+ years in a similar role.

Project management experience preferred.

§ Preferred specific composites and aerospace industry experience.

PHYSICAL DEMANDS:

The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

While performing the duties of this Job, the employee is regularly required to talk or hear. The employee is frequently required to sit, stand, walk, stoop, kneel or crouch; use hands to finger, handle, or feel and reach with hands and arms.

WORK ENVIRONMENT:

The work environment is primarily within the manufacturing facilities, with moderate to loud noise levels expected from the operation of machinery.

All American Racers is an equal opportunity employer.