Senior Design Engineer

The Structures Company, LLC; Santa Ana (CA); On-site; USD 140,000 - 190,000; Full time

Job summary

The Structures Company, LLC seeks a Sr. Composite Design Engineer to lead complex design efforts for aerospace composite structures from concept to production.

You will drive structural optimization, ensure manufacturability, and align designs with program requirements, collaborating cross-functionally to deliver high-performance components. Responsibilities include leading 3D modeling and drawings, laminate schedules, and structural analyses with stress teams, while coordinating with

Qualifications

• Bachelor’s degree in Aerospace Engineering, Mechanical Engineering, Materials Science, or related field.
• 10+ years in a similar role in aerospace composites.
• Experience with high-performance composite structures and certification standards (AS9100).

Responsibilities

• Lead design and development of composite structures, ensuring performance, weight, cost, and manufacturability.
• Create and review 3D models, drawings, and release packages using CAD software.
• Develop laminate schedules, ply books, and stack-ups aligned with load cases.
• Perform structural analysis with stress engineering for strength, stiffness, fatigue, and damage tolerance.
• Interface with manufacturing, tooling, quality, and supply chain to enable DFM and production transition.
• Support prototype builds, FAI, and ramp activities, resolving technical issues.
• Participate in material and process selection (autoclave, OOA, RTM) and design trade studies.
• Generate and maintain engineering documentation (specifications, reports, change notices).
• Support customer technical reviews, design audits, and certification activities.
• Drive continuous improvement in composite design standards and processes.

Skills

Composite design

CAD modeling

FEA

CATIA

NX

SolidWorks

DFM

Laminate theory

AS9100

Education

Bachelor's degree in Aerospace Engineering

Master's degree preferred

Tools

CATIA

NX

SolidWorks

Job description

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.

• 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.