Senior Design Engineer

Senior Design Engineer

Location: Houston, TX

Overview: We are seeking a highly skilled Senior Design Engineer with a unique blend of experience in downhole oil & gas equipment design and composites technology. The ideal candidate will possess a strong background in mechanical engineering, coupled with expertise in the design, analysis, and manufacturing of composite materials for downhole applications.

Responsibilities:

Composite Design Expertise: Lead the design and development of downhole drilling and completion tools with a focus on incorporating composite materials for enhanced performance, durability, and corrosion resistance.

Material Selection: Evaluate and select appropriate composite materials, resins, and reinforcements based on application requirements, environmental conditions, and performance specifications.

Structural Analysis: Conduct structural analysis and simulation studies to assess the mechanical integrity, load-bearing capacity, and fatigue life of composite components, ensuring compliance with industry standards and safety regulations.

Hybrid Design Integration: Collaborate with cross-functional teams to integrate composite components with traditional metal structures, optimizing design configurations for weight reduction, cost efficiency, and reliability.

Manufacturing Process Optimization: Work closely with manufacturing engineers to optimize composite manufacturing processes, including layup techniques, curing cycles, and quality control procedures, to achieve consistent and repeatable results.

Prototype Development: Lead the fabrication and testing of composite prototypes, analyze test data, and iterate designs to optimize performance and address any design challenges or deficiencies.

Documentation and Reporting: Prepare comprehensive design documentation, including material specifications, CAD models, technical reports, and test plans, to document design decisions and facilitate communication with stakeholders.

Risk Management: Identify and mitigate potential risks associated with composite design and manufacturing processes, proactively addressing issues related to material compatibility, structural integrity, and regulatory compliance.

Requirements:

Bachelor's degree in Mechanical Engineering, Materials Science, or related field; Master's degree preferred.

Minimum of 5 years of experience in downhole oil & gas equipment design, with a focus on composite materials and structural engineering.

Proficiency in CAD software (e.g., SolidWorks, CATIA) and finite element analysis (FEA) tools (e.g., ANSYS, Abaqus) for composite structural analysis.

Strong understanding of composite materials and manufacturing processes, including filament winding, resin infusion, and autoclave curing.

Experience with composite characterization techniques, such as mechanical testing, thermal analysis, and non-destructive testing (NDT).

Demonstrated ability to manage complex engineering projects, from concept development through prototyping and commercialization, with a track record of successful product launches.

Excellent communication skills, with the ability to collaborate effectively with multidisciplinary teams and present technical concepts to internal and external stakeholders.

Preferred Qualifications:

Experience with downhole tool qualification testing according to industry standards (e.g., API, ISO).

Knowledge of corrosion protection techniques and coatings for composite materials in aggressive downhole environments.

Familiarity with composite failure analysis methods, including fracture mechanics and fatigue analysis.

Prior experience in technology transfer and scaling up composite manufacturing processes from laboratory-scale to production-scale.

Strong project management skills, including budgeting, resource allocation, and milestone tracking.