Senior Structural Analysis Engineer

About the Role
We are seeking a Structural Analysis Engineer with Composite background to join our engineering team. This role combines advanced structural analysis with hands-on knowledge of polymer composite manufacturing and design. The ideal candidate will bridge the gap between theoretical analysis and practical fabrication, ensuring our composite structures are optimized for both performance and manufacturability. Knowledge in high temperature composite material and having a dynamics analysis background is a plus.
Key Responsibilities
• Perform structural analysis of composite components using finite element analysis (FEA) tools (ANSYS, Abaqus, NASTRAN, or similar)
• Knowledge of classical laminate theory and composite hand calculation methods
• Conduct stress analysis, failure prediction, and damage tolerance assessments for composite laminates and structures
• Develop and validate composite layup schedules considering manufacturing constraints and structural requirements
• Support design reviews with analysis-driven recommendations on fiber orientation, ply stacking sequences, and material selection
• Collaborate with manufacturing teams to ensure designs are producible and address fabrication challenges
• Perform trade studies comparing composite materials, processes, and configurations
• Support testing programs including correlation of analytical models with test data
• Generate technical reports, analysis documentation, and design justification packages
• Support nonconformances during prototype, development and manufacturing trials
• Interface with customers, suppliers, and cross-functional teams on composite structural requirements
Required Qualifications
• Bachelor's degree in Aerospace Engineering, Mechanical Engineering, or related field
• 5+ years of experience in composite structural analysis
• Proficiency with FEA software (ANSYS, Abaqus, NASTRAN, or equivalent)
• Working knowledge of composite materials (carbon fiber, fiberglass, Kevlar) and manufacturing processes (hand layup, autoclave cure, filament winding, RTM)
• Understanding of composite failure theories (Tsai-Wu, Tsai-Hill, Hashin, etc.)
• Experience with composite design principles and laminate theory
• Strong analytical and problem-solving skills
• Excellent written and verbal communication abilities
Preferred Qualifications
• Master's degree in relevant engineering discipline
• 10+ years of experience in composite structural analysis
• Hands-on experience with composite fabrication or manufacturing engineering
• Knowledge of aerospace or defense industry standards (MIL-HDBK-17, NCAMP, CMH-17)
• Experience with composite design software (HyperSizer, ESAComp, Fibersim, or similar)
• Familiarity with test methods (ASTM D3039, D3410, D5528, etc.)
• Background in rocket motor cases, pressure vessels, or aerospace structures
• Knowledge in high temperature composite material systems
• Programming/scripting skills (Python, MATLAB) for analysis automation
• Experience in mechanical dynamics, vibration analysis, shock response, and environmental loading principles.
• Active security clearance or ability to obtain one
ITAR Requirements
To conform to U.S. Government space technology export regulations, including the International Traffic in Arms Regulations (ITAR), you must be a U.S. citizen, lawful permanent resident of the U.S., a protected individual as defined by 8 U.S.C. 1324b(a)(3), or eligible to obtain the required authorizations from the U.S. Department of State.
Work Environment and Physical Requirements
This position requires mobility across manufacturing, testing, machine shop, and outdoor test environments. Duties may include walking, climbing, lifting up to 25 pounds, and working in high-hazard areas with appropriate PPE. Personal protective equipment such as safety glasses, safety shoes, hearing protection, flame-resistant clothing, and respiratory protection may be required based on task demands. The role may involve varying work hours including early mornings, nights, or weekends to support operations or facility maintenance activities.
Security Clearance
May be required to obtain and maintain a U.S. Security Clearance at the appropriate level. Requires U.S. Citizenship and ability to meet federal requirements for access to sensitive information.
Benefits at Firehawk Aerospace
• 100% employer-paid medical premiums for employees and up to 75% for dependents on select plans
• Affordable dental and vision plans with extensive coverage
• Employee Assistance Program including counseling, legal services, and wellness resources
• Flexible 9/80 work schedule option
• On-site snacks and refreshments
• Mentorship opportunities and involvement in advanced aerospace projects
Firehawk Aerospace is an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to protected characteristics.