Senior Composite Structures Analysis Engineer

Dimensions IT Services; Addison (TX); On-site; USD 110,000 - 160,000; Full time

Benefits offered by this job

100% employerpaid medical premiums for

Dental and vision plans

Employee Assistance Program

Flexible 9/80 work schedule

Onsite snacks and refreshments

Mentorship opportunities

Job summary

Firehawk Aerospace in Addison, TX is seeking a Structural Analysis Engineer with a composite background to bridge theoretical analysis with practical fabrication. You will ensure optimized performance and manufacturability of composite structures.

Responsibilities include FEA-based stress analysis, layup schedule development, design reviews, and collaboration with manufacturing teams to address fabrication challenges. 5+ years in composite analysis and strong communication are required.

Qualifications

• Bachelor's degree in Aerospace or Mechanical Engineering or related field.
• 5+ years of experience in composite structural analysis.
• Proficiency with FEA software (ANSYS, Abaqus, NASTRAN, or equivalent).
• Working knowledge of composite materials (carbon fiber, fiberglass, Kevlar) and manufacturing processes (hand layup, autoclave cure, filament winding, RTM).
• Understanding of composite failure theories (TsaiWu, TsaiHill, Hashin, etc.).
• Experience with composite design principles and laminate theory.
• Strong analytical and problemsolving skills.
• Excellent written and verbal communication abilities.

Responsibilities

• Perform structural analysis of composite components using finite element analysis (FEA) tools (ANSYS, Abaqus, NASTRAN, or similar).
• Knowledge of classical laminate theory and composite hand calculation methods.
• Conduct stress analysis, failure prediction, and damage tolerance assessments for composite laminates and structures.
• Develop and validate composite layup schedules considering manufacturing constraints and structural requirements.
• Support design reviews with analysis-driven recommendations on fiber orientation, ply stacking sequences, and material selection.
• Collaborate with manufacturing teams to ensure designs are producible and address fabrication challenges.
• Perform trade studies comparing composite materials, processes, and configurations.
• Support testing programs including correlation of analytical models with test data.
• Generate technical reports, analysis documentation, and design justification packages.
• Support nonconformances during prototype, development and manufacturing trials.
• Interface with customers, suppliers, and crossfunctional teams on composite structural requirements.

Skills

FEA proficiency

Analytical skills

Communication skills

Dynamics analysis

Problem solving

Collaboration

Manufacturing awareness

Python/MATLAB scripting

Test data correlation

Education

Bachelor's degree in Aerospace or Mechanical Engineering

Master's degree in a relevant engineering discipline

10+ years composite structural analysis experience

Tools

ANSYS

Abaqus

NASTRAN

HyperSizer

ESA Comp

Fibersim

Job description

Firehawk Aerospace in Addison, TX is seeking a Structural Analysis Engineer with a composite background to bridge theoretical analysis with practical fabrication. You will ensure optimized performance and manufacturability of composite structures.

Responsibilities include FEA-based stress analysis, layup schedule development, design reviews, and collaboration with manufacturing teams to address fabrication challenges. 5+ years in composite analysis and strong communication are required.