Staff Design Engineer, Solid Rocket Motor Cases

Ursa Major; Berthoud (CO); On-site; USD 143,000 - 179,000; Full time

Benefits offered by this job

Unlimited PTO

Parental and adoptive leave

Medical, dental and vision insurance

HSA/FSA accounts

Disability and life insurance

Job summary

Ursa Major is seeking a Staff Design Engineer to own the design, development, and qualification of solid rocket motor primary and secondary structures. You will drive end‑to‑end programs from concept through scalable production, collaborating with analysis, manufacturing, test, and supply chain teams.

You will work hands-on on the build floor, leading design decisions, test campaigns, and documentation while mentoring less‑senior engineers and codifying best practices. This role requires U.S.

Qualifications

• Bachelor’s degree in aerospace or mechanical engineering required.
• 7+ years in rocket motors, solid propulsion, pressure vessels, or high‑performance structural interfaces.
• Ability to execute clean‑sheet rocket motor case designs and initial structural analyses.
• Proficiency with CAD and engineering analysis tools (FEA, pressure vessel, basic thermal).
• Strong fundamentals in structural mechanics, materials, and stress analysis; basic thermodynamics and fluid dynamics as they relate to SRM.

Responsibilities

• Own design of composite or metallic rocket motor cases and interfaces.
• Translate requirements into manufacturable structural designs meeting performance targets.
• Lead design trades across materials, layups, processes, and configurations.
• Develop and execute test campaigns from coupon to full-scale testing.
• Review data, identify anomalies, and drive design/process improvements.
• Provide hands-on support for hardware assembly and testing on the floor.

Skills

Structural design of rocket motors

CAD (Siemens NX)

FEA / structural analysis

Test planning and execution

Cross-functional collaboration

Documentation & compliance

Education

Bachelor’s degree in aerospace or mechanical engineering

Master’s or PhD (preferred)

Tools

Siemens NX

ANSYS

Job description

The future of aerospace and defense starts here.

Ursa Major was founded to revolutionize how America and its allies access and apply high-performance propulsion, from hypersonics to solid rocket motors, satellite maneuvering and launch. We design and deliver propulsion and defense systems that solve the most urgent and critical national security demands.

Ursa Major’s solid rocket motor (SRM) team is hiring multiple Staff Design Engineers to own the design, development, and qualification of solid rocket motor primary structures (motor cases) and key secondary structures. This is a senior, highly technical role with end-to-end responsibility: from clean-sheet concept through qualification and scalable production.

You will be a technical owner for SRM design at Ursa Major, defining structural architectures and interfaces, leading composite or metallic case design, and driving test campaigns. You’ll play a key role in establishing the design methods, standards, and processes that enable scalable, high-rate production of solid rocket motor structures.

This isn’t purely a desk job. You’ll be expected to be on the build floor working with technicians, integrating hardware, and resolving build issues in real time. Our engineers work across a variety of programs and roles, so you’ll have the opportunity to contribute beyond your title and take on new challenges as they arise.

What You’ll Do

• Own clean-sheet design of composite or metallic rocket motor cases and mechanical interfaces (e.g., attachment points, skirts, fin clips/rails).
• Translate customer requirements and mission needs into robust, manufacturable structural designs that meet performance, reliability, cost, and schedule targets.
• Lead design trades across materials, layup architectures, manufacturing processes, and structural configurations.
• Develop and execute test campaigns (coupon through full-scale testing) to derisk new case designs and mature them into qualified products.
• Review test data to verify performance against predictions, identify anomalies, and drive design or process changes when needed.
• Provide hands‑on support for hardware assembly and test, including troubleshooting manufacturing, integration, and structural performance issues.
• Lead cross-functional collaboration with analysis, manufacturing, test, systems, and supply chain teams to ensure case designs meet all stakeholder needs.
• Establish and maintain aggressive but realistic development schedules, identifying technical and programmatic risks early and implementing mitigation plans.
• Generate, review, and approve CAD models and engineering drawings in accordance with internal standards and ASME Y14.5‑2009/2018.
• Maintain rigorous technical documentation: requirements, design reviews, test plans and reports, verification/validation evidence, and customer deliverables.
• Serve as a technical mentor for less-senior engineers, providing guidance on structural design, analysis, materials, manufacturing, and integration.
• Codify best practices by authoring design standards, guidelines, checklists, and processes to drive consistency and quality across the SRM case and structural portfolio.

Required Qualifications

• Bachelor’s degree in aerospace engineering, mechanical engineering, or a related field.
• Minimum of 7 years of relevant experience with rocket motors, solid propulsion elements, pressure vessels, or high‑performance structural interfaces.
• Ability to execute clean‑sheet rocket motor case designs, including initial structural analyses to inform geometry, materials, and sizing.
• Proficiency with CAD and engineering analysis tools (e.g., structural/FEA, pressure vessel analysis, basic thermal analysis).
• Strong engineering fundamentals, including in‑depth knowledge of structural mechanics, materials, and stress analysis; familiarity with thermodynamics and fluid dynamics as they relate to solid rocket motor design.
• Clear, effective written and verbal communication skills for cross‑functional collaboration, design reviews, customer discussions, and documentation.
• Eligibility for a U.S. DoD Secret Clearance is required and maintaining that eligibility is a condition of employment.

Desired Experience

• Master’s degree or PhD in mechanical engineering, aerospace engineering, or a related technical discipline.
• Experience:
• designing for, and working with, elastomeric materials (e.g., seals, boots, liners, vibration isolation).
• conducting insensitive munitions testing and product qualification for solid rocket motors or related systems.
• designing hardware for high‑rate, automated production, including DFM/DFA and process automation.
• with composite material design and manufacturing (i.e., flat panels, filament wound structures).
• with high‑strength metallic alloys and associated forming and joining methods.
• Hands‑on involvement in rapid product development environments (prototype‑heavy, fast‑iteration programs).
• Proficiency with Siemens NX (CAD) and Ansys (FEA) tools.
• Active DoD Secret Clearance or higher.

Colorado law requires us to tell you the base compensation range of this role, which is $143,360.00 - $179,200.00 , determined by your education, experience, knowledge, skills, and abilities. What we can't quantify for you are the exciting challenges, supportive team, and amazing culture we enjoy.

Classification: Full-time Exempt

Benefits Include: (Please note, Interns are not eligible for benefits)

• Unlimited PTO - Vacation, Sick, Personal, and Bereavement
• Paid Parental and Adoptive Leave
• Medical, Dental and Vision Insurance
• Tax Advantage Accounts (HSA/FSA)
• Employer Paid Short and Long Term Disability, Basic Life, AD&D
• Additional Benefit Options Including Voluntary Life and Emergency Medical Transport
• EAP Program
• Retirement Savings Plan - 401k with Company Match

Must be a U.S. Person (this includes U.S. Citizens and Permanent Residents)

Eligibility to obtain and maintain a U.S. Security Clearance

We’re an equal-opportunity employer. You will be considered for employment without attention to race, color, religion, sex, sexual orientation, gender identity, national origin, veteran, or disability status.

No outside recruiters, please.