Senior Aircraft Structures Designer

Structures.Aero; Sterling (VA); Hybrid; USD 110,000 - 165,000; Full time

Benefits offered by this job

Full medical, dental, vision insurance

401k with company matching

Paid leave that scales with experience

Paid parental leave

Job summary

Structures.Aero in Sterling, VA, is seeking a Senior Aircraft Structures Designer to lead the structural design of aircraft components and assemblies, focusing on composite and metallic structures from concept through detailed design and manufacturing support.

You will develop 3D models and drawings, define load paths, and collaborate with stress analysts, manufacturing engineers, and program managers to meet performance, weight, certification targets.

Qualifications

• Expertise in aircraft structural design for composite and metallic components.
• Experience with bonded/bolted joints and load-bearing assemblies.
• Collaborates with stress analysts on ply modeling and sizing.
• Familiarity with procurement, aeroelastic considerations, and design reviews.
• Knowledge of aerospace standards, certification requirements, and documentation.

Responsibilities

• Lead structural design of aircraft components and assemblies from concept through detailed design.
• Develop 3D models and drawings; define layouts and load paths for certification.
• Collaborate with stress analysts, manufacturing engineers, and program managers.
• Support design reviews, configuration management, and process improvements.
• Mentor less-experienced designers and ensure compliance with standards.

Skills

Aircraft structural design

Stress analysis collaboration

Aerospace materials knowledge

Design for manufacturability

Problem solving

Strong communication

Tools

CATIA

NX

SolidWorks

Job description

Company Description

Structures.Aero (SDA) engineers the future of flight by delivering advanced structural design and analysis solutions for mission-critical aerospace and defense programs. With nearly three decades of experience, the team supports demanding air and space platforms, including next-generation UAVs, manned aircraft, orbital vehicles, and reentry systems. SDA’s core strength is composite-focused engineering, helping clients improve performance, reduce weight, and accelerate certification, whether transitioning from metallics or optimizing existing structures. The company provides full-spectrum support across the product lifecycle from conceptual design and stress analysis to validation, testing, and manufacturing support. SDA’s team has been major contributors on iconic platforms such as the B-2 Stealth Bomber, F-22 Raptor, NASA’s Orion Crew Module, Boom XB-1, Electra EL-2, AAI Aerosonde, Blue Origin’s Human Landing System, and multiple other aerospace programs.

Role Description

The Senior Aircraft Structures Designer is a full-time, role based in Sterling, VA with hybrid work options available. This position is responsible for leading the structural design of aircraft components and assemblies, with a focus on composite and metallic structures, from concept through detailed design and manufacturing support. Day-to-day tasks include developing 3D models and drawings in aerospace CAD tools, defining structural layouts and load paths, collaborating closely with stress analysts, manufacturing engineers, and program managers, and ensuring designs meet performance, weight, certification, and cost targets. The role involves reviewing requirements, performing trade studies, integrating analysis results into design decisions, and supporting design reviews and configuration management. The Senior Aircraft Structures Designer also mentors less-experienced designers, contributes to process improvement, and helps ensure designs comply with aerospace standards, customer specifications, and regulatory guidelines. Rare occasional travel to customer locations and manufacturing sites.

Qualifications

• Demonstrated expertise in aircraft structural design, including composite and metallic components, bonded/bolted joints, and load-bearing assemblies.
• Proficiency with leading aerospace CAD tools (e.g., CATIA, NX, SolidWorks) for 3D modeling, drawing creation, GD&T, and configuration control.
• Ability to collaborate effectively with stress analysts on ply modeling, sizing, aeroelastic considerations, and integration of analysis into design.
• Experience supporting the full product lifecycle: conceptual design, detailed design, stress analysis collaboration, validation, testing, and manufacturing support.
• Strong understanding of aerospace materials, manufacturing processes (especially composites), and design for manufacturability and assembly.
• Knowledge of relevant aerospace standards, certification requirements, and documentation practices for defense and commercial programs.
• Excellent problem-solving skills, attention to detail, and ability to manage multiple design tasks in a fast-paced environment.
• Effective verbal and written communication skills, with the ability to present
• Full medical, dental, vision insurance coverage
• 401k with company matching and immediate vesting
• Paid leave that scales with experience level
• Paid parental leave