Structures Design Engineer II

Karman Space & Defense; Washington (District of Columbia); On-site; USD 85,000 - 115,000; Full time

Benefits offered by this job

Medical Insurance

401k with match

Paid Time Off

Health Savings Account

Flexible Spending Accounts

Life and AD&D insurance

Short- and long-term disability

Tuition reimbursement

Job summary

Karman Space & Defense in Washington, DC is seeking a Structures Design Engineer II to design aerospace structures, mechanisms, and tooling with a focus on advanced composite materials. You will create models, drawings, and specifications; perform analyses; support manufacturing and testing; and collaborate with customers and internal partners to deliver flight‑worthy designs.

The role requires a DoD Secret security clearance or ability to obtain one, a bachelor's degree in mechanical

Qualifications

• Bachelor’s degree in mechanical engineering or equivalent.
• 2–5 years of aerospace or defense hardware design experience.
• Proficiency in mechanical design, drawing conventions, and CAD/CAE tools.
• Knowledge of composite part and tool manufacturing.

Responsibilities

• Conceptualizes, develops, and designs structures, tooling, and mechanisms using advanced composites.
• Creates CAD models at component and assembly level.
• Produces drawings and defines BOMs, manufacturing requirements, and inspection criteria.
• Implements GD&T and performs basic mechanical calculations.
• Reviews designs for cost, manufacturability, and quality assurance.
• Supports manufacturing, testing, and deployment activities from concept to delivery.
• Mentors junior engineers and contributes to proposals.

Skills

Composite materials

CATIA V5

CAD/CAE

GD&T

Education

Bachelor’s degree in mechanical engineering

Tools

CATIA V5

CATIA Composite Work Bench

Job description

Job Description

Karman Space & Defense is a leader in the rapid design, development, and production of critical, next‑generation system solutions that align with the U.S. Department of War and its allies’ core mission priorities, and meet the accelerating demand for access to space. Building on nearly 50 years of success, we deliver Payload & Protection Systems, Aero/Hydrodynamic Interstage Systems, and Propulsion & Launch Systems to more than 80 prime contractors supporting over 130 space and defense programs. This role is part of our Hypersonics and Strategic Missile Defense business, which designs, develops, and delivers highly dependable missile systems for hypersonic and strategic missile defense missions. We provide integrated, mission‑ready hardware that brings together multiple technologies into unified systems engineered to perform in demanding operational environments. Our tip‑to‑tail capabilities include payload protection and deployment systems, propulsion systems, aerodynamic interstage systems, separation systems, missile subsystems, shroud systems, launch systems, and payload integration solutions. As a Structures Design Engineer II, you will design and develop aerospace structures, mechanisms, and tooling with a primary focus on advanced composite materials. You will create models, drawings, and specifications; perform engineering analyses; support manufacturing and testing; and collaborate with customers and internal partners to deliver high‑quality, flight‑worthy designs. You will also contribute to proposals and mentor junior engineers, ensuring designs meet functional, performance, and compliance requirements from concept through deployment.

Responsibilities

• Conceptualizes, develops, and designs structures, tooling, and mechanisms based on customer requirements, with a focus on advanced composite components.
• Creates component and assembly‑level computer‑aided design (CAD) models.
• Produces engineering drawings and defines bills of materials, manufacturing requirements, and inspection criteria in accordance with standards and specifications.
• Implements geometric tolerancing and performs basic mechanical engineering calculations.
• Reviews designs for cost, manufacturability, and quality assurance considerations.
• Provides technical support to customers throughout the design process.
• Identifies and specifies off‑the‑shelf mechanical components, selects vendors, and supports purchasing to meet delivery timelines.
• Documents performance requirements, compliance, plans, test procedures, test reports, and other contractual specifications.
• Supports manufacturing, quality assurance, testing, and deployment activities from concept to delivery.
• Contributes to proposals and presentations for business development and market surveys.
• Performs engineering analyses to ensure safe operation and compliance with designated requirements.
• Mentors junior engineers and provides technical guidance.

Required Qualifications

• Bachelor’s degree in mechanical engineering or equivalent experience and registration.
• Typically 2–5 years of aerospace or defense hardware design experience.
• Proficiency in mechanical design, engineering fundamentals, and drawing conventions.
• Knowledge of composite part and tool manufacturing.
• Experience with computer‑aided design and engineering (CAD/CAE) tools for mechanical systems.
• Proficient with CATIA Version 5 (V5); experience with CATIA Composite Work Bench preferred.
• Proficient in Geometric Dimensioning and Tolerancing (GD&T).
• Knowledge of design‑based military and commercial specifications.
• Ability to work independently, multitask, and maintain a strong focus on quality and safety.
• Strong mechanical aptitude and creativity in solving technical problems.
• Excellent communication and customer‑relationship skills.
• A current U.S. Department of Defense (DoD) Secret security clearance or the ability to obtain and maintain one.

Benefits

• Medical, dental, and vision insurance
• 401(k) with company match
• Paid time off
• Health Savings Account (HSA) with company contribution
• Flexible Spending Accounts (FSA)
• Company‑paid life and AD&D insurance
• Short‑ and long‑term disability coverage
• Tuition reimbursement

Karman Space and Defense is an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, national origin, age, disability, genetic information, protected veteran status, or any other status protected by applicable law.