Senior Structures Design Engineer

About the role

Astro-mechanica is developing advanced high-speed supersonic flight platforms powered by proprietary Duality propulsion technology with the goal of revolutionizing global transportation. This position centers on leading the structural design of primary airframe assemblies, guiding them from preliminary concepts all the way through to qualified flight hardware. You will function within a rapid, hands-on engineering culture where establishing design standards and steering the development of major structural elements are daily expectations. The role demands a blend of deep technical expertise and leadership to define how critical load-bearing components are conceived, analyzed, and manufactured.

Key facts

What you'll do

• Assume end-to-end ownership of major structural modules such as wing boxes, fuselage barrels, or empennage sections, driving them through the complete product lifecycle.
• Define structural load paths, select appropriate materials, design joints and fittings, and develop manufacturing strategies for both advanced composite laminates and metallic alloys.
• Partner closely with stress analysts to refine designs using classical hand calculations alongside detailed finite element analysis correlation.
• Execute comprehensive trade studies that balance structural performance, mass efficiency, recurring cost targets, and production feasibility constraints.
• Synchronize structural configuration and interface definitions across propulsion integration, aerodynamics loads groups, and ground and flight test organizations.
• Generate and maintain high-fidelity parametric CAD models, detailed engineering drawings, and supporting technical documentation packages.
• Direct fabrication oversight, coordinate structural ground test campaigns, and support flight test operations to validate designs and implement rapid design iterations.
• Mentor junior structural engineers, conduct design reviews, and formalize internal best practices, design guidelines, and checking procedures.

Requirements

• Bachelor of Science or Master of Science in Aerospace Engineering, Mechanical Engineering, or a closely related technical field.
• Minimum of eight years of professional experience in aircraft structural design with a demonstrated track record of delivering flight-qualified hardware.
• Proven history of shepherding structural designs from initial conceptual layout through detailed design, manufacturing release, test verification, and certification support.
• Deep, practical expertise in the design of both composite and metallic primary structures, including bolted and bonded joining techniques, load introduction methods, and damage tolerance principles.
• Advanced proficiency in Siemens NX for complex assembly management, parametric modeling, and drawing production, or equivalent high-end CAD systems.
• Strong command of first-principles structural sizing methods and hands-on experience with finite element pre and post-processing tools such as Femap with Nastran solvers.
• Demonstrated ability to make sound technical judgments with incomplete data and communicate complex engineering rationale clearly to multidisciplinary stakeholders.

Nice to have

• Direct experience designing structures for supersonic or hypersonic vehicles where thermal-structural coupling is a primary driver.
• Background in designing pressure vessels, cryogenic tanks, or hot structures compatible with advanced propulsion cycles.
• Familiarity with additive manufacturing design rules for metallic aerospace components and associated qualification pathways.
• Experience with model-based systems engineering (MBSE) workflows and requirements management tools like Jama or DOORS.
• Prior involvement in FAA Part 25 or experimental aircraft certification processes and compliance documentation.
• Exposure to automated composite manufacturing processes such as automated fiber placement (AFP) or automated tape laying (ATL).

Skills & tools

• Siemens NX (Advanced Assembly, Routing, Drafting)
• Femap / Nastran (Linear and Nonlinear Static, Buckling, Modal)
• Composite laminate design, ply book generation, and stacking sequence optimization
• Metallic detail design: machining, sheet metal, forging, and casting specifications
• First-principles hand calculation methods for beam theory, plate buckling, and joint analysis
• GD&T per ASME Y14.5 for aerospace tolerance stack-ups
• PLM integration (Teamcenter preferred) for configuration management

Practical notes

• This position requires on-site presence at the San Francisco facility five days per week with no remote or hybrid arrangement offered.
• Comprehensive benefits package includes medical, dental, and vision insurance coverage, flexible spending accounts, a 401(k) retirement plan, and an equity incentive stock option program.
• Flexible time-off policy encompasses paid time off, sick leave, and observed company holidays without strict accrual caps.
• Visa sponsorship eligibility is assessed on a case-by-case basis; candidates requiring work authorization should indicate status during application.
• Relocation assistance may be available for qualified candidates relocating to the Bay Area.
• Pre-employment background check and drug screening are standard conditions of offer.
• Work environment involves frequent interaction with composite layup areas, machine shops, and test facilities requiring appropriate PPE.