Structural Design Engineer

ACE Partners; United States; On-site; USD 90,000 - 120,000; Full time

Job summary

ACE Partners is supporting an innovative aerospace company in its search for an experienced Airframe Designer to join its engineering team.

This role will own the detailed design of primary and secondary airframe structures for a new generation of unmanned aircraft, from concept through to release drawings.

You will work cross-functionally with manufacturing, quality, supply chain and technicians to ensure designs are manufacturable, scalable and ready for higher-rate production.

Qualifications

• Bachelor’s degree in Aerospace Engineering, Mechanical Engineering or a related technical discipline.
• 5+ years of hands-on structural, airframe or mechanical design experience.
• Proven experience taking a structural design from concept through detailed design, released drawings and physical manufacture or assembly.
• Strong proficiency with 3D CAD software such as SolidWorks, CATIA or similar platforms.
• Strong knowledge of GD&T and tolerance stack-up analysis.
• Practical understanding of structural design fundamentals including load paths, joints, fasteners, fatigue, corrosion and weight optimization.
• Experience designing components for manufacturing processes such as CNC machining, sheet metal fabrication, composites, welding or additive manufacturing.
• Experience working directly with machinists, technicians, manufacturing engineers and external suppliers.
• Ability to produce clear and accurate technical drawings and assembly documentation.
• Comfortable working in a fast-moving engineering environment where engineers are expected to take ownership from initial concept through to finished hardware.

Responsibilities

• Design primary and secondary airframe structures from initial concept through to production-ready drawings.
• Develop structural designs with a strong focus on Design for Manufacturing and Assembly (DFM/DFA), including reducing part count, simplifying assembly and standardizing components and features.
• Select appropriate materials, manufacturing methods and joining techniques based on cost, production rate, tooling requirements and lead times.
• Develop assembly concepts, build sequences, fixtures and tooling requirements alongside manufacturing teams.
• Produce and maintain detailed 3D CAD models, assembly drawings and manufacturing drawings.
• Apply GD&T and tolerance stack-up principles to ensure components and assemblies meet functional and manufacturing requirements.
• Perform first-order structural sizing, load-path assessments and margin calculations, while coordinating more detailed stress analysis where required.
• Design structural joints, interfaces, mounting provisions and removable or serviceable assemblies.
• Support prototype builds, integration and flight-test activities by resolving fit, interference and manufacturing issues.
• Review and disposition non-conformances and implement design changes while maintaining configuration control.
• Work closely with suppliers and internal manufacturing teams to review DFM feedback, quotations and manufacturing approaches.
• Support make-versus-buy decisions and the sourcing of fabricated structural components.
• Maintain released drawings, bills of material and configuration documentation throughout the development process.

Skills

3D CAD

GD&T

DFM/DFA

Structural design

Manufacturing liaison

Education

Bachelor's in Aerospace/Mechanical

Tools

SolidWorks

CATIA

Job description

ACE Partners is supporting an innovative aerospace company in the search for an experienced Airframe Designer to join its engineering team.

This position will take ownership of the detailed design of primary and secondary airframe structures across a new generation of unmanned aircraft. The role is highly hands-on and will cover the full design lifecycle, from early concept development through detailed design, released drawings, manufacturing support and aircraft build.

A key focus of the position will be ensuring designs are practical, manufacturable and scalable. The successful candidate will work closely with engineering, manufacturing, quality, supply chain and technicians to develop structural solutions that can be built efficiently today and transitioned into higher-rate production in the future.

Responsibilities

• Design primary and secondary airframe structures from initial concept through to production-ready drawings.
• Develop structural designs with a strong focus on Design for Manufacturing and Assembly (DFM/DFA), including reducing part count, simplifying assembly and standardizing components and features.
• Select appropriate materials, manufacturing methods and joining techniques based on cost, production rate, tooling requirements and lead times.
• Develop assembly concepts, build sequences, fixtures and tooling requirements alongside manufacturing teams.
• Produce and maintain detailed 3D CAD models, assembly drawings and manufacturing drawings.
• Apply GD&T and tolerance stack-up principles to ensure components and assemblies meet functional and manufacturing requirements.
• Perform first-order structural sizing, load-path assessments and margin calculations, while coordinating more detailed stress analysis where required.
• Design structural joints, interfaces, mounting provisions and removable or serviceable assemblies.
• Support prototype builds, integration and flight-test activities by resolving fit, interference and manufacturing issues.
• Review and disposition non-conformances and implement design changes while maintaining configuration control.
• Work closely with suppliers and internal manufacturing teams to review DFM feedback, quotations and manufacturing approaches.
• Support make-versus-buy decisions and the sourcing of fabricated structural components.
• Maintain released drawings, bills of material and configuration documentation throughout the development process.

Requirements

• Bachelor’s degree in Aerospace Engineering, Mechanical Engineering or a related technical discipline.
• 5+ years of hands-on structural, airframe or mechanical design experience.
• Proven experience taking a structural design from concept through detailed design, released drawings and physical manufacture or assembly.
• Strong proficiency with 3D CAD software such as SolidWorks, CATIA or similar platforms.
• Strong knowledge of GD&T and tolerance stack-up analysis.
• Practical understanding of structural design fundamentals including load paths, joints, fasteners, fatigue, corrosion and weight optimization.
• Experience designing components for manufacturing processes such as CNC machining, sheet metal fabrication, composites, welding or additive manufacturing.
• Experience working directly with machinists, technicians, manufacturing engineers and external suppliers.
• Ability to produce clear and accurate technical drawings and assembly documentation.
• Comfortable working in a fast-moving engineering environment where engineers are expected to take ownership from initial concept through to finished hardware.

Preferred Experience

• Experience within UAV, UAS, eVTOL, rotorcraft or other advanced aerospace development programs.
• Previous experience within a startup, prototype development program or small engineering team.
• Experience transitioning products from prototype development into low-rate or higher-volume production.
• Candidates from automotive, motorsport or other advanced structural design environments may also be considered where they can demonstrate strong DFM/DFA and production design experience.