Seeking an experienced
Mechanical/Aerospace Engineer to lead the structural, thermal, and aerodynamic design, analysis, and qualification of advanced missile airframes, control surfaces, and internal mechanical packaging.
In this role within the Hardware & Avionics IPT, you will work closely with the
SME / Lead Developer to translate aerodynamic profiles and 6-DOF trajectory loads into flight-ready airframe structures, Thermal Protection Systems (TPS), and mechanical interfaces for Control Actuation Systems (CAS) and propulsion units.
Key Responsibilities1. Airframe Design, Packaging, & Aerothermal Analysis- Lead the mechanical architecture and CAD modeling of missile airframes, rseekers, body tubes, fins/canards, and internal mounting structures using 3D CAD (Siemens NX, CATIA, or SolidWorks).
- Execute structural, modal, and aerothermal Finite Element Analysis (FEA using ANSYS or NASTRAN) to verify structural integrity, thermal margins, and dynamic response under extreme flight loads (supersonic/hypersonic aerodynamic drag, extreme G-forces, and friction heating).
- Perform mass properties management (center of gravity, moments of inertia, total mass budgets) and work with the GNC team to maintain aerodynamic stability profiles.
2. Mechanical Integration with CAS, Propulsion, & Avionics- Collaborate with the SME / Lead Developer to integrate Control Actuation Systems (CAS)-including fin shafts, high-torque gearboxes, linkage assemblies, and actuator housings-ensuring minimal mechanical backlash and compliance under heavy aerodynamic loads.
- Design ruggedized mechanical enclosures, mounting chassis, and vibration-isolation assemblies for sensitive onboard avionics, Inertial Measurement Units (IMUs), power electronics, and thermal batteries.
- Manage mechanical interfaces with solid rocket motors ensuring proper thrust vector alignment, thermal isolation, and structural load paths.
3. Material Selection & Advanced Manufacturing- Select high-performance aerospace materials suited for harsh flight environments.
- Apply Design for Manufacturability and Assembly (DFMA) principles, coordinating with machine shops, composite fabricators, and additive manufacturing vendors to ensure cost-effective, high-precision production.
4. Environmental Qualification & Field Testing- Author test plans and lead environmental qualification testing for structural airframes and mechanical sub-assemblies (static load tests, modal survey, thermal vacuum / TVAC, random vibration, acoustic loading, and pyroshock per MIL-STD-810).
- Deploy to remote proving grounds and flight test ranges to support hardware assembly, launcher mechanical integration, pre-flight checks, and post-flight recovery/inspection.
- Participate in Failure Review Boards (FRBs) chaired by the Chief Engineer to perform root-cause failure analysis on structural or mechanical anomalies.
Required Qualifications & Technical Stack- Education: B.S. in Mechanical Engineering, Aerospace Engineering, or a related discipline with 5+ years of experience (or M.S. with 3+ years) in missile, rocket, or high-performance aerospace structures.
- CAD & FEA Tools:
- Advanced proficiency in 3D CAD modeling (Siemens NX, CATIA V5/3DEXPERIENCE, or SolidWorks).
- Strong hands-on expertise in FEA modeling software (ANSYS, NASTRAN, Abaqus, or FEMAP) for structural, thermal, and dynamic stress analysis.
- Aerothermal & Material Knowledge:
- Deep understanding of high-speed aerodynamics, thermal protection systems (TPS), aero-heating load prediction, and structural dynamics (vibration/shock).
- In-depth knowledge of aerospace materials (titanium, carbon composites, high-temperature alloys, ablatives) and precision manufacturing processes.
- Security Clearance: Must hold an active US DoD Secret security clearance
