Senior Staff Aerostructures Design Engineer (R5846)

Dallas · San Diego · Remote · USD 170,000-260,000 / year · 10+ years experience · Posted Sep 24, 2026

At a glance

The Senior Staff Aerostructures Design Engineer will own the design and development of high-performance structural systems for next-generation autonomous aircraft.
This role involves managing the structural design lifecycle from clean-sheet concepts to production-ready hardware while working across multidisciplinary teams.

Lead the design and development of structural components and assemblies for next-gen UAV platforms.
Own the structural design lifecycle including concept generation, CAD modeling, detail design, and drawing release.
Use FEA tools to perform and guide linear and nonlinear structural analysis, stress analysis, and margin assessment.
Collaborate with aerodynamics, propulsion, avionics, payload, and manufacturing teams for system integration.
Lead material selection efforts focusing on composites, aluminum alloys, and advanced manufacturing.
Lead design reviews, architecture discussions, and technical decision-making forums.
Oversee the design and execution of structural validation testing at coupon, subcomponent, and system levels.
Guide the development of design documentation and verification plans in compliance with MIL-STD and FAA standards.
Mentor junior engineers and review team members’ work for technical rigor and manufacturability.
Collaborate with manufacturing and flight test teams to transition designs to production and field deployment.

Bachelor’s or Master’s degree in Mechanical Engineering, Aerospace Engineering, or a related discipline.
10+ years of experience in aircraft structural design with demonstrated ownership of components or systems.
Deep understanding of composite and metallic structures, including material behavior, joints, and thermal/environmental effects.
Expertise in CAD tools (NX, CATIA, or SolidWorks) and FEA tools (ANSYS, Abaqus, NASTRAN, or similar).
Experience conducting or overseeing stress analysis, fatigue analysis, and design optimization.
Strong working knowledge of DFMA, GD&T, tolerance stackups, and structural layout principles.
Clear, concise technical communication skills and experience leading cross-functional engineering efforts.
Track record of technical excellence, high ownership, and a mission-driven mindset.

Ability to get a S//SAR level security clearance.
M.S. degree in Aerospace or Mechanical Engineering.
Strong NX CAD skills.
Experience supporting or leading Group 3–5 UAV, DoD aircraft, or high-performance aerospace vehicle programs.
Knowledge of aerospace standards (MIL-STD, ASME Y14.5, FAA FARS) and certification pathways.
Prior experience in flight vehicle integration, manufacturing liaison, or production support.
Familiarity with model-based engineering, digital twin development, or configuration management tools.
Demonstrated experience in failure analysis, design iteration, and test correlation.

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