Senior Design Engineer

Insight Global; Berthoud (CO); On-site; USD 106,000 - 132,000; Full time

Job summary

Insight Global's client is seeking a Senior Design Engineer to own the design, analysis, development, and qualification of solid rocket motor primary structures, cases, mechanisms, and assemblies. The role emphasizes additive manufacturing, high-rate production, automation, and reducing touch labor, with opportunities to lead hardware from concept through production.

Qualifications include 5+ years in mechanical or aerospace engineering, DoD clearance eligibility, and experience with NX/Ansys;

Qualifications

• Bachelor’s degree in mechanical or aerospace engineering.
• 5+ years of relevant experience.
• Experience designing rocket motors and propulsion hardware.
• Strong solid mechanics and engineering fundamentals.
• Experience with CAD/analysis tools; Siemens NX/Ansys preferred.
• Experience with metal additive manufacturing design.
• DoD Secret clearance eligibility; active clearance preferred.
• Master’s degree or PhD is a plus.

Responsibilities

• Own clean-sheet design of solid rocket motor hardware.
• Apply solid mechanics to component and system design.
• Translate requirements into reliable, cost-effective designs.
• Design hardware for additive manufacturing and high-rate production.
• Lead design from concept to prototype, assembly, testing, and qualification.
• Review test results and implement design changes.
• Develop aggressive product schedules and mitigate risks.
• Provide dispositions for nonconforming hardware.
• Create and approve CAD models, drawings, and docs per ASME Y14.5-2009.
• Collaborate across engineering, manufacturing, procurement, and supply chain.

Skills

Solid mechanics

Additive manufacturing

High-rate production design

Cross-functional collaboration

Problem solving

Prototype development

Education

Bachelor’s degree in Mechanical/Aerospace Engineering

Master’s degree or PhD in Mechanical/Aerospace Engineering

DoD Secret clearance eligibility

Tools

Siemens NX

ANSYS

Job description

Job Description

Insight Global's client is looking for a Senior Design Engineer. The Senior Design Engineer will help own the design, analysis, development, and qualification of solid rocket motor primary structures, including motor cases, mechanical components, mechanisms, assemblies, secondary structures, and related propulsion systems. This role requires a strong background in solid mechanics and the ability to take hardware from clean-sheet design through manufacturing, assembly, testing, qualification, and production.

Additive manufacturing is a significant part of the product strategy, so this individual should have strong experience designing metal hardware for additive manufacturing and an understanding of emerging manufacturing technologies. The ideal candidate will also have experience designing hardware and manufacturing processes for high-rate production, automation, scalability, and reduced touch labor.

Key Responsibilities:

• Own clean-sheet design and development of solid rocket motor hardware, including motor cases, mechanisms, structural components, and assemblies.
• Apply solid mechanics and structural engineering principles from component-level design through integrated systems.
• Translate customer and internal requirements into reliable, cost-effective designs.
• Design hardware for additive manufacturing, high-rate production, automation, and reduced touch labor.
• Lead design development from concept through prototype manufacturing, assembly, testing, and qualification.
• Review test results, troubleshoot hardware, and implement design changes as needed.
• Develop and maintain aggressive but achievable product schedules while identifying and mitigating design risks.
• Provide engineering dispositions for discrepant or nonconforming hardware, including supporting analysis as needed.
• Create and approve CAD models, drawings, and engineering documentation in accordance with internal requirements and ASME Y14.5-2009.
• Collaborate across engineering, manufacturing, testing, procurement, and supply chain to address design, production, and technical risks.

Salary range: $105,840- $132,300

Skills and Requirements

• Bachelor’s degree in mechanical engineering, Aerospace Engineering, or a related field with 5+ years of relevant experience.
• Experience designing rocket motors, solid propulsion hardware, primary structures, motor cases, mechanisms, components, and/or assemblies.
• Strong solid/structural mechanics and engineering fundamentals, including thermodynamics and fluid dynamics.
• Experience taking hardware from clean-sheet design through manufacturing, assembly, testing, and qualification.
• Experience with CAD and engineering analysis tools. Specific software packages are not required.
• Strong understanding of metal additive manufacturing, including design, material, and process limitations.
• Ability to collaborate across engineering, manufacturing, testing, supply chain, and customer teams.
• Understanding of insensitive munitions principles related to solid rocket motor design.
• Must be eligible to obtain and maintain a DoD Secret clearance.
• Master’s degree or PhD in Mechanical Engineering, Aerospace Engineering, or a related technical field.
• Experience with insensitive munitions testing and product qualification.
• Hands-on experience with rapid product development.
• Experience designing hardware for high-rate or automated production.
• Composite overwrap and filament winding design/analysis experience.
• Experience with Siemens NX, Ansys, or similar engineering software.
• Active DoD Secret clearance or higher.

We are a company committed to creating diverse and inclusive environments where people can bring their full, authentic selves to work every day. We are an equal employment opportunity/affirmative action employer that believes everyone matters. Qualified candidates will receive consideration for employment without regard to race, color, ethnicity, religion, sex (including pregnancy), sexual orientation, gender identity and expression, marital status, national origin, ancestry, genetic factors, age, disability, protected veteran status, military or uniformed service member status, or any other status or characteristic protected by applicable laws, regulations, and ordinances. If you need assistance and/or a reasonable accommodation due to a disability during the application or the recruiting process, please send a request to [e-mail].