Structures Design Engineer- Staff/Senior

Position Overview

At Aurora Flight Sciences, we design, build, and fly advanced aircraft and enabling technologies from concept to reality. We are searching for a talented and self-motivated Structures Design Engineer- Staff/Senior to help us create the future of flight. Responsibilities will include but not be limited to the following:

Responsibilities

Technical Leadership:

• Provide the first line of technical authority within the design team, with responsibility for approving design concepts and determining technical objectives for projects.
• Lead by example, mentoring and guiding junior engineers while working independently for extended periods.

Design and Development:

• Create airframe structural configuration layouts and detailed designs, including preliminary sizing, joint layouts, and interface boundary definitions for parts and assemblies, working with both metallic and composite materials.
• Develop and maintain CAD models and drawings of installations, assemblies, and detail components, ensuring strict adherence to structural integrity, interface boundaries, weight, and cost targets.
• Conduct design reviews and validate product structures to ensure components meet functional, fit, and form requirements.

Project Execution:

• Assume ownership of project execution and integration, leading teams of engineers to deliver against program budgets and deadlines.
• Coordinate with stress, manufacturing, procurement, and quality control teams to mature designs from initial conception to full-scale production.
• Track weekly progress and maintain project documentation to ensure alignment with program milestones.

Cross-Functional Collaboration:

• Collaborate effectively with manufacturing and tooling teams for prototyping, material selection, and production strategies, particularly for composite components.
• Prepare and present technical and programmatic data during Preliminary Design Reviews (PDRs) and Critical Design Reviews (CDRs).

Mentorship and Training:

• Offer technical guidance and mentorship to team members, including junior designers, to achieve high-quality deliverables.

Minimum Requirements

• Ability to obtain a US Security Clearance for which the US Government requires US Citizenship.
• Bachelor’s Degree in Mechanical Engineering, Aerospace Engineering, or a related discipline.
• Minimum of 5 years of experience in aerospace or related fields.
• Competence with CAD software, particularly CATIA V5, SmarTeam, or similar product data management systems (e.g., Enovia LCA or PDM).
• Knowledge of industry standards relating to composite component design, manufacturing, repair, and assembly (specific to aerospace).
• Proficiency with Microsoft Office 365 (Excel, Word, and PowerPoint).
• Strong verbal and written communication skills with a collaborative mindset.

Preferred Requirements

• Expertise in CATIA V5 modules, including Generative Surface Design, Part Design, and Assembly (experience with Unigraphics or Siemens NX will be considered).
• Advanced knowledge of composite material structures, including design, stacking sequences, lamination theory, bonded assemblies, and post-cure machining operations.
• Familiarity with prototype and rate production, including exposure to manufacturing tooling design, planning, and hands-on fabrication.
• Geometric Dimensioning and Tolerancing (GD&T): Knowledge of ASME Y14.5 and related tolerance analysis techniques.
• Experience with Model-Based Definition (MBD): Familiarity with ASME Y14.41 methods and CATIA V5 FTA for functional tolerancing and annotations.
• Strong foundation in manufacturing and development of aerospace structural components and assemblies.

Physical Requirements

• Ability to work on-site on a weekly basis at our Manassas, VA or Cambridge, MA locations.

Salary Range (Annualized USD)

• Minimum Range: $92,000.00 to $164,000.00
• Maximum Range: $112,000.00 to $199,000.00

Aurora Company Overview Aurora Flight Sciences, a Boeing Company, is a leader in the development and manufacturing of advanced unmanned systems and aerospace vehicles. Our mission is to apply autonomy and robotics to the development, production, and operation of advanced aircraft. During the last three decades, Aurora has designed, rapid-prototyped, and flown an average of one new vehicle a year for both government and commercial customers. Now, as an independent subsidiary of Boeing, Aurora’s innovation is combined with Boeing’s size and strength, creating an unprecedented opportunity to shape the future of aerospace systems.

Equal Opportunity Employer Aurora Flight Sciences, A Boeing Company, is an Equal Opportunity Employer. Employment decisions are made without regard to race, color, religion, national origin, gender, sexual orientation, gender identity, age, physical or mental disability, genetic factors, military/veteran status or other characteristics protected by law.

Aurora Total Rewards At Aurora Flight Sciences, a Boeing Company, we strive to deliver a Total Rewards package that will attract, engage and retain the top talent. Elements of the Total Rewards package include competitive base pay and variable compensation opportunities. Aurora Flight Sciences provides eligible employees with an opportunity to enroll in a variety of benefit programs, generally including health insurance, flexible spending accounts, health savings accounts, retirement savings plans, life and disability insurance programs, and a number of programs that provide for both paid and unpaid time away from work. The specific programs and options available to any given employee may vary depending on eligibility factors such as geographic location and date of hire. Please note that the salary information shown is a general guideline only. Salaries are based upon candidate experience and qualifications, as well as market and business considerations.