Aero-Structural Design and Manufacturing Engineer

About the Role

As an Aero-Structural Design and Manufacturing Engineer at Booz Allen Hamilton, you will contribute to the development of next-generation defense tools and technology. You will utilize your engineering expertise in the design of metallic and composite aircraft components, coupons, and related tooling and test fixtures. This role supports stress analysis, load prediction, structural life forecasting, and structural integrity analysis for innovative aerospace solutions. You will provide expertise in evaluating new technologies, performing risk assessments, and improving the design of aerospace systems as part of a prototype design team.

Key Responsibilities

• Design of metallic and composite aircraft components, coupons, and related tooling and test fixtures.
• Support stress analysis and load prediction.
• Support structural life forecasting.
• Support structural integrity analysis for new and innovative aerospace solutions.
• Provide expertise in evaluating new technologies.
• Perform risk assessments.
• Improve the design of aerospace systems.
• Contribute to the direction of mission-critical solutions.
• Work in a team environment alongside structural analysts, material science engineers, test engineers, machinists, and researchers.

Requirements & Tech Stack

• Design software: AutoCAD, UG, SolidWorks, CATIA, or Pro-Engineer.
• Finite element methods and software tools: ABAQUS, ANSYS, NASTRAN, PATRAN, or MATLAB.
• Knowledge of metallic and composite structural design, analysis, and fabrication.
• Knowledge of composite fabrication, assembly, and testing.
• Knowledge of manufacturing and design techniques, procedures, and practices.
• Knowledge of basic machine shop equipment, including drill presses, grinders, band saws, shears, hand layout tools, and machine shop tools and practices.
• Ability to work in and around large irregular shaped parts.
• Ability to obtain a Secret clearance.

Qualifications

• Bachelor's degree in Mechanical Engineering or Aerospace Engineering.
• Experience with design, analysis, or fabrication in the aerospace industry.
• Experience using design software.
• Experience using finite element methods and software tools.

Nice to Have

• Experience using probabilistic composite structure stress, buckling and vibrational analysis methods, and hand calculations of Rourk and Bruhn.
• Experience with aircraft structural layout and sizing.
• Experience with aero-structural design using composite materials.
• Experience with design for manufacturing techniques and procedures.
• Experience with design and analysis of carbon fiber reinforced polymers, glass fiber reinforced plastics, discontinuous fiber composites, or ceramic matrix and high temperature composites.
• Knowledge of composite-related nondestructive inspection, procedures, practices, and test processes in engineering.
• Secret clearance.
• Master's degree in Mechanical Engineering or Aerospace Engineering.
• Military Aircraft Structural Integrity Programs (ASIP) Certification.

Compensation

The projected compensation range for this position is $69,300.00 to $158,000.00 (annualized USD).

Work Model

• Remote: May require occasional work in person at a Booz Allen or customer facility.
• Hybrid: Expected to work from a Booz Allen or customer facility.
• Onsite: Primarily performed full-time at a customer facility.

Clearance

Applicants selected will be subject to a security investigation and may need to meet eligibility requirements for access to classified information.