Senior Aerospace Design Lead - CAD, Reverse Engineering, PM

Expleo Group; Bingen (WA); On-site; USD 180,000 - 220,000; Full time

Benefits offered by this job

Competitive compensation up to $200k

Medical, Dental, Vision

HSA with company contribution

401(k) with matching

Paid holidays and PTO

Job summary

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.

The role demands leadership of design projects, hands-on expertise with CAD (SolidWorks), 3D scanning, GD&T, and PDM-driven documentation, with collaboration across Airbus programs and UAS platforms.

Qualifications

• Bachelor's degree in mechanical or aerospace engineering.
• 10+ years 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 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.

Responsibilities

• Lead reverse engineering using 3D scanning 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.
• 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.
• 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.
• 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.
• 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.

Skills

SolidWorks

3D scanning

GD&T

PDM systems

CNC programming

Reverse engineering

Aerospace design

Airbus programs experience

UAS/UAV experience

Education

Bachelor's Degree in Mechanical or Aerospace Engineering

Tools

CNC programming software

PDM software

3D scanning equipment

Job description

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.

The role demands leadership of design projects, hands-on expertise with CAD (SolidWorks), 3D scanning, GD&T, and PDM-driven documentation, with collaboration across Airbus programs and UAS platforms.