Design Engineer (Composites)

About the role

Firehawk Aerospace is seeking a Design Engineer with composite structures expertise to support the design and development of advanced composite components for munitions and propulsion systems. The position will report directly to the Design Engineering Manager and will support all areas of the organization (Design, Analysis, Testing, Manufacturing, etc.). The ideal candidate should be an effective communicator who works well in teams and with limited supervision. They should possess a broad knowledge and experience with composite structural design, analysis, and manufacturing processes for aerospace applications. The ideal candidate should be considered a subject matter expert or a recognized technical lead for composite design, laminate optimization, and the transition of composite structures from development to production.

Responsibilities

• Lead/mentor other engineers in the design and development of structures for rocket motors, pressure vessels, and airframe components with emphasis on composite materials
• Create/modify CAD models and associated drawings for parts, assemblies, and tooling
• Develop composite layup schedules, ply stacking sequences, and fiber orientation strategies that balance structural performance with manufacturing constraints
• Work with analysis/fluids/manufacturing/testing teams to iterate designs and ensure producibility
• Support manufacturing operations including composite processes (hand layup, autoclave cure, filament winding, RTM) and conventional fabrication methods
• Make project decisions based on technical merit, cost, schedule metrics, and manufacturing feasibility
• Analyze and interpret test data from mechanical testing to validate designs and improve structural performance
• Perform trade studies comparing materials, processes, and configurations to optimize design solutions
• Collaborate with other engineers and project leads to meet project goals
• Generate technical reports, analysis documentation, and design justification packages
• Support nonconformances during prototype, development, and manufacturing trials
• Ensure that all designs and processes comply with governmental regulations, industry standards (MILHDBK17, NCAMP, CMH17), and safety requirements

Basic Qualifications

• Bachelor's degree in aerospace engineering, mechanical engineering, materials engineering, or related field
• 3+ years of professional experience in mechanical design with composite structures focus
• 3+ years of experience with CAD software (CREO preferred, SOLIDWORKS, NX, or CATIA)
• Working knowledge of composite materials (carbon fiber, fiberglass, Kevlar) and manufacturing processes (hand layup, autoclave cure, filament winding, RTM)
• Proficient with GD&T, tolerance analysis, and design for manufacturability
• Experience with PLM software (Windchill preferred)
• General understanding of manufacturing processes (welding, machining, heat treating, composite fabrication)
• Capability to manage project efforts and solve complex problems
• Strong work ethic and ability to thrive in a fast-paced R&D environment
• Self-motivated with strong organizational, written, and oral communication skills
• Focus on safety, reliability, innovation, efficiency, and teamwork
• Ability to earn trust and maintain positive and professional relationships
• Proficiency with Microsoft Office products (Word, Excel, PowerPoint, OneNote)
• U.S. Citizenship
• Ability to lift 25 pounds and work on test/flight hardware
• Must be willing to travel as required (approximately 10%)

Preferred Qualifications

• Master's degree in aerospace engineering, mechanical engineering, materials engineering, or related field
• 5+ years of professional experience in mechanical design and development with composite structures emphasis
• 5+ years of experience with CREO and Windchill
• Hands-on experience with composite fabrication or manufacturing engineering
• Professional experience designing/testing rocket motor cases, pressure vessels, or aerospace structures
• Experience with composite design software (HyperSizer, ESAComp, Fibersim, or similar)
• Working knowledge of FEA software (ANSYS, Abaqus, NASTRAN, or equivalent)
• Understanding of composite failure theories, classical laminate theory, and composite design principles
• Strong understanding of structural analysis and failure modes of mechanical systems
• Knowledge of high-temperature composite material systems (polyimides, bismaleimides, ceramic matrix composites)
• Experience in mechanical dynamics, vibration analysis, shock response, and environmental loading principles
• Familiarity with aerospace or defense industry standards and qualification processes
• 2+ years of project management experience
• Background in both development and production environments
• Active or previous security clearance

Work Environment

Employees in these positions must possess mobility to work in a standard office setting and to use standard office equipment, including a computer; stamina to sit and to maintain attention to detail despite interruptions; may occasionally lift/carry/push/pull up to 25 pounds; may require minimal walking, standing for extended amounts of time, climbing, crouching, and/or bending; and vision to read printed materials and a computer screen, and hearing and speech to communicate in person and over the telephone. May require the ability to travel by air or auto. May require the use of personal protective equipment such as safety glasses, safety shoes, and shop coat.