UAS Composites Engineer

Heven AeroTech; Sterling (VA); On-site; USD 70,000 - 150,000; Full time

Benefits offered by this job

Medical, dental, and vision coverage

Retirement plans

Paid time off and sick leave

Job summary

Heven AeroTech is seeking a UAS Composites Engineer in Sterling, Virginia, focused on the design and development of advanced unmanned aerial systems. The role requires expertise in composite materials, CAD tools, and integration of payload systems.

Candidates should have over 7 years of relevant experience and possess a strong background in structural analysis, systems-level thinking, and design-for-manufacturing principles. The position offers a competitive salary range of $70,000 - $150,000 USD and a robust benefits package.

Qualifications

• 7+ years of experience in UAS, aerospace, or related industries.
• Strong experience with composite materials and fabrication methods.
• Understanding of structural analysis and basic FEA tools.

Responsibilities

• Design, analyze, and optimize composite airframe structures.
• Develop CAD models and documentation for composite components.
• Lead integration of payload systems across teams.

Skills

Composite materials and fabrication methods

CAD tools proficiency (SolidWorks, CATIA, NX)

Rapid prototyping

Problem-solving and analytical skills

Understanding of structural analysis

Education

Bachelor’s or Master’s degree in Aerospace Engineering, Mechanical Engineering, or related field

Tools

SolidWorks

CATIA

NX

Job description

Title: UAS Composites Engineer

Company: Heven AeroTech

Location: Sterling, Virginia

FLSA: Exempt

About Our Company

Heven AeroTech (Heven) is a recognized leader in hydrogen‑powered drones. We create a workplace where innovation thrives, collaboration is common, and every employee feels valued. Our culture is anchored in trust and a shared commitment to excellence.

Role Summary

We are seeking a highly skilled UAS Engineer with a focus on composite structures and payload integration to support design, development, and deployment of advanced unmanned aerial systems (UAS). This role bridges airframe engineering and mission capability, ensuring that composite structures and payload systems are efficiently integrated, structurally sound, and optimized for performance.

The ideal candidate combines hands‑on experience with composite materials, strong systems‑level thinking, and a design‑for‑manufacturing mindset to integrate sensors, electronics, and mission‑specific payloads into robust, flight‑ready platforms.

Key Responsibilities

• Design, analyze, and optimize highly manufacturable composite airframe structures (fuselage, wings, mounts, enclosures), applying Design for Manufacturing principles to ensure scalable and reliable production.
• Select appropriate composite materials (carbon fiber, fiberglass, resins, cores) based on performance, weight, reliability, and manufacturability trade‑offs.
• Develop CAD models, drawings, and documentation for composite components using tools such as SolidWorks, CATIA, or NX.
• Perform structural analysis (FEA, hand calculations) to validate strength, stiffness, durability, and performance margins with attention to detail and analytical rigor.
• Support fabrication processes including layup, curing, trimming, and finishing with a focus on repeatable, high‑quality manufacturing outcomes.
• Lead integration of payload systems including sensors, cameras, communication modules, and mission‑specific equipment, ensuring cross‑disciplinary collaboration across mechanical, electrical, and software teams.
• Define mechanical, electrical, and thermal interfaces between payloads and airframe, ensuring robust integration and system reliability.
• Design mounting solutions that ensure stability, vibration isolation, serviceability, and operational durability.
• Manage payload weight, balance, and power constraints while applying systems thinking to evaluate impacts on flight performance, CG, endurance, and structural loads.
• Conduct trade studies to balance payload capability with range, endurance, and overall mission performance.
• Support system architecture development and configuration control across evolving UAS platforms.
• Plan and execute ground and flight tests for structural and payload validation, leveraging test data to iterate and improve designs.
• Troubleshoot integration issues in fast‑paced development cycles and implement effective corrective actions.
• Develop and document repeatable manufacturing processes for composite components in collaboration with suppliers and internal teams.
• Support transition from prototype to low‑rate and full‑rate production environments.

Required Qualifications

• 7+ years of experience in UAS, aerospace, or related industries.
• Strong experience with composite materials and fabrication methods.
• Proficiency in CAD tools (SolidWorks, CATIA, NX, or equivalent).
• Experience with payload integration at the mechanical and/or systems level.
• Understanding of structural analysis and basic FEA tools.
• Familiarity with UAS platforms, flight dynamics, and system‑level constraints.
• Strong problem-solving and analytical skills with a focus on reliability and performance.
• Ability to work effectively in fast‑paced, iterative engineering environments.
• Strong communication skills and ability to collaborate across engineering disciplines.

Preferred Qualifications

• Bachelor’s or Master’s degree in Aerospace Engineering, Mechanical Engineering, or related field.
• Experience with small to medium UAS platforms.
• Knowledge of vibration isolation and thermal management for payload systems.
• Hands‑on experience with composite layup and rapid prototyping.
• Familiarity with avionics, sensors, and communication systems.
• Experience with 3D printing, CNC machining, and tooling design.
• Understanding of regulatory considerations (FAA, MIL standards, etc.).

Benefits Overview

Heven AeroTech offers a competitive benefits package, including medical, dental, and vision coverage; retirement plans; paid time off and sick leave; and additional protections such as critical illness, hospital indemnity, accident coverage, and short‑ and long‑term disability.

Equal Employment Opportunity Statement

Heven AeroTech is an Equal Opportunity Employer and considers all qualified applicants without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, disability, veteran status, or any other protected characteristic under applicable law.

Salary Range: $70,000 - $150,000 USD