Weld Engineer - Launch Vehicle Structures

LEAP; Broomfield (CO); Hybrid; USD 130,000 - 160,000; Full time

Benefits offered by this job

Equity program

401(k) plan with company match

Professional development stipend

Unlimited PTO

Hybrid work model

Job summary

LEAP is seeking a Launch Vehicle Structures Weld Engineer to lead welding process design, qualification, and production support for propellant tanks and unpressurized structures on suborbital and orbital launch vehicles in Colorado. You will own weld procedure qualification, joint design, fixturing, and distortion control to ensure flight-worthy welds.

Collaboration with NDE, stress teams, and fixture design is essential.

Qualifications

• Bachelor’s degree in Welding Engineering, Materials Science, Mechanical Engineering, or related field. (Required)
• 5+ years of experience developing and qualifying weld processes for aerospace or high-performance pressure vessels. (Required)
• Strong understanding of weld setup, joint design, fixturing, and distortion control.
• Strong understanding of weld metallurgy, defects, and NDE methods.
• Ability to work directly on the shop floor in a fast-paced startup environment.
• Experience operating under aggressive schedules with flight-critical hardware.

Responsibilities

• Develop, qualify, and maintain welding procedures (WPS/PQR) for propellant tanks and pressure vessels, ensuring weld processes are certified, repeatable, and compliant with structural, fracture-control, and pressure-vessel requirements for flight hardware
• Define weld joint designs, fit-up requirements, and weld sequencing in collaboration with design and structures teams, ensuring load paths, distortion control, and structural margins are maintained while enabling repeatable, high-quality production welds
• Establish process windows, parameter control, and acceptance criteria, resulting in reduced variability, fewer weld defects, and improved first-pass inspection acceptance
• Support tooling design and fixture development to control alignment and distortion, ensuring dimensional accuracy, structural integrity, and repeatable weld quality across production hardware
• Troubleshoot weld defects, distortion, and variability to maintain qualified welding processes and consistent production performance
• Provide daily support to tank fabrication and assembly operations, ensuring welding processes are executed correctly, issues are resolved in real time, and production progresses safely, efficiently, and to flight-quality standards

Skills

Weld setup understanding

Joint design & fixturing

Distortion control

Weld metallurgy & NDE

Shop floor execution

Flight-critical hardware experience

Education

Bachelor’s degree in Welding Engineering, Materials Science, Mechanical Engineering

Job description

The Launch Vehicle Structures Weld Engineer is responsible for developing, qualifying, and sustaining all welding and joining processes used in the fabrication of flight propellant tanks and unpressurized structures for LEAPS suborbital and orbital launch vehicles. This role owns weld process design, procedure qualification, tooling collaboration, inspection coordination, and production support ensuring welds meet structural, fracture, and quality requirements for flight hardware. This role collaborates with weld technicians, fixture design engineers, NDE, and stress teams to deliver repeatable, certifiable, and flight-worthy welds.

Impacts & Outcomes

• Develop, qualify, and maintain welding procedures (WPS/PQR) for propellant tanks and pressure vessels, ensuring weld processes are certified, repeatable, and compliant with structural, fracture-control, and pressure-vessel requirements for flight hardware
• Define weld joint designs, fit-up requirements, and weld sequencing in collaboration with design and structures teams, ensuring load paths, distortion control, and structural margins are maintained while enabling repeatable, high-quality production welds
• Establish process windows, parameter control, and acceptance criteria, resulting in reduced variability, fewer weld defects, and improved first-pass inspection acceptance
• Support tooling design and fixture development to control alignment and distortion, ensuring dimensional accuracy, structural integrity, and repeatable weld quality across production hardware
• Troubleshoot weld defects, distortion, and variability to maintain qualified welding processes and consistent production performance
• Provide daily support to tank fabrication and assembly operations, ensuring welding processes are executed correctly, issues are resolved in real time, and production progresses safely, efficiently, and to flight-quality standards

What You Bring to the Team

• Bachelor’s degree in Welding Engineering, Materials Science, Mechanical Engineering, or related field. (Required)
• 5+ years of experience developing and qualifying weld processes for aerospace or high-performance pressure vessels. (Required)
• Strong understanding of weld setup, joint design, fixturing, and distortion control.
• Strong understanding of weld metallurgy, defects, and NDE methods.
• Ability to work directly on the shop floor in a fast-paced startup environment.
• Experience operating under aggressive schedules with flight-critical hardware.

Bonus Points

• Prior work on launch vehicles, spacecraft, or flight pressure vessels.
• Experience working to AWS D17.1 and AIAA S-080 standards.
• Experience working in handheld laser and robotic laser weld cells.
• Experience with laser welding of thin-wall aerospace structures.
• Background working in startup or rapid-development environments.

Compensation

Salary Range: $130,00 - 160,000

The estimated salary range for this role reflects various compensation factors. The final offer depends on factors such as work experience, education, training, key skills, and business needs.

In addition, LEAP provides a comprehensive benefits package for full-time employees, which includes:

• Equity Program: Equity plan participation is available to all employees following an initial 90-day employment period and is performance-based. Equity allocations are determined on a case-by-case basis and are not guaranteed. Managers may make recommendations based on individual and team performance. All equity grants are subject to executive review and approval in accordance with the Company’s equity plan.
• Retirement Planning: Save for the future with a 401(k) plan that includes competitive company matching.
• Growth Opportunities: Take advantage of a professional development stipend to advance your skills and expertise.
• Flexible Time Off: We encourage taking time off when you need it. Our policy includes unlimited PTO, generous holiday breaks, two week-long company winter shutdowns, and paid leave for family care, parental bonding, or personal health needs.
• Remote Work Flexibility: Our team operates on a hybrid model. We expect you to work with your team for specific details on work location.
• Health Benefits: LEAP provides comprehensive medical, dental, and vision coverage at minimal to no cost for employees. Coverage for dependents and HSA are also available.
• Insurance Coverage: We cover basic life and long-term disability insurance, with options to add extra coverage to ensure peace of mind for you and your family.

Equal Opportunity Employment

LEAP is proud to be an equal-opportunity employer committed to building a diverse and inclusive workplace in Colorado. Our team brings together exceptionally talented and diverse individuals who are pushing the boundaries of space access and logistics. We welcome all qualified applicants and provide equal consideration for employment regardless of race, color, religion, sex, gender identity, sexual orientation, national origin, disability, Veteran status, age, or any other protected characteristic under federal, state, or local law. This includes individuals with a criminal history, in compliance with applicable regulations. We actively encourage applications from minorities, women, Veterans, and people with disabilities. At LEAP, we strive to create a supportive and welcoming environment throughout the hiring process. If you’re excited about making a real-world impact in space technology, we want to hear from you!