Structures Design Engineer III

Karman Space & Defense; Washington (District of Columbia); On-site; USD 110,000 - 140,000; Full time

Benefits offered by this job

Medical, dental and vision

401(k) with company match

Paid time off

HSA with company contribution

FSA

Life and AD&D insurance

Disability coverage

Tuition reimbursement

Job summary

Karman Space & Defense seeks a Mechanical Design Engineer to create aerospace structures and mechanisms using advanced composite materials. You will drive concepts from design through deployment, produce CAD models and drawings, perform analyses, and collaborate with manufacturing, QA, and test teams to ensure flight‑worthy hardware.

You will work independently on multiple tasks, apply GD&T, and balance performance with cost and quality, contributing to DoD-aligned programs and supplier

Qualifications

• Bachelor's degree in Mechanical Engineering or equivalent
• 4–7 years aerospace/defense hardware design experience
• Proficient in CAD/CAE tools and drawing conventions
• Strong GD&T knowledge and mechanics background
• Ability to work independently with minimal oversight

Responsibilities

• Conceptualizes, designs structures, tooling, and mechanisms with composites emphasis
• Creates CAD models at component and assembly level
• Produces drawings, defines BOMs, and inspection criteria
• Implements GD&T and performs strength calculations
• Leads subsystem design and validates analysis for safe operation
• Reviews designs for cost, manufacturability and quality
• Supports procurement and vendor alignment with delivery needs
• Documents performance requirements, tests, and specs
• Supports manufacturing, QA, testing, and deployment
• Mentors junior engineers and supports business development

Skills

Mechanical design

Engineering drawings

GD&T

Independent work

Communication skills

Problem solving

Education

Bachelor's degree in Mechanical Engineering

Tools

CATIA V5

Generative Shape Design

Composite Work Bench

Job description

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.

In this role, you will design and develop aerospace structures and mechanisms with a strong focus on advanced composite materials. You will drive engineering solutions from concept through deployment, create detailed models and drawings, perform analysis, and collaborate closely with manufacturing, quality assurance, and test teams. Your work will directly support the delivery of flight‑worthy hardware and ensure designs meet performance, cost, and quality requirements.

Responsibilities

• Conceptualizes, develops, and designs structures, tooling, and mechanisms with an emphasis 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.
• Implements geometric dimensioning and tolerancing (GD&T) and performs mechanical strength calculations.
• Leads subsystem design efforts and validates analysis to ensure safe operation in meeting requirements.
• Reviews designs for cost, manufacturability, and quality assurance considerations.
• Identifies off‑the‑shelf components, selects vendors, and supports procurement activities aligned with delivery needs.
• Documents performance requirements, customer compliance, plans, test procedures, test reports, and contractual specifications.
• Supports manufacturing, quality assurance, testing, and deployment activities from concept to delivery.
• Supports business development efforts and mentors junior engineers.

Required Qualifications

• Bachelor’s degree in Mechanical Engineering or equivalent combination of relevant experience and registration.
• Typically possesses 4–7 years of aerospace and/or defense hardware design experience.
• Demonstrated proficiency in mechanical design, engineering, and drawing conventions.
• Knowledge of computer‑aided design/computer‑aided engineering (CAD/CAE) tools relevant to mechanical systems design.
• Proficient with CATIA V5, Generative Shape Design (GSD), and Composite Work Bench.
• Proficient with geometric dimensioning and tolerancing (GD&T) methods.
• Detailed knowledge of design‑based military and commercial specifications.
• Strong mechanical aptitude with the ability to solve complex problems and balance big‑picture goals with detailed execution.
• Ability to work independently with minimal oversight while managing multiple tasks.
• Excellent communication and customer‑relationship skills.

Preferred Qualifications

• Hands‑on experience with composite part and tool manufacturing.
• 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.