Lead, Structural Engineering 1 1

Job Title: Lead Structural Engineer

Job Code: 23956

Job Location: Huntsville

Job Schedule: 9/80 schedule. Employees work 9 out of every 14 days – totaling 80 hours worked – and have every other Friday off

Job Description:

Join our team shaping the next generation of solid rocket propulsion systems. We are seeking a Structural Engineer for our Huntsville, AL location with deep expertise in composite pressure vessel analysis to join our rocket propulsion team. This role focuses on structural analysis of filament-wound composite motor cases but provides flexibility to support metallic and conventional components across the broader propulsion system. Ideal candidates will bring a blend of advanced composite mechanics, structural modeling, and hands-on engineering judgment, with optional background in case design or tooling support. As an internal expert, you will lead and support structural modeling and analysis efforts for solid rocket motor (SRM) components throughout the product lifecycle—from early development through qualification and production. You will collaborate closely with cross-disciplinary teams, interface with customers, and drive technical excellence.

Essential Functions:

Lead structural analysis of filament-wound composite pressure vessels and overwrapped hardware for solid rocket motors.

Apply advanced composite theory—including classical lamination theory, micromechanics, and shear lag modeling—to evaluate stresses, strains, and failure modes in anisotropic materials.

Perform closed-form and finite element analyses to assess strength, stability, and margin of safety for composite cases and metallic substructures.

Utilize orthotropic material modeling and thermal-mechanical coupling in FEA tools With ANSYS MAPDL and ACP Prep/Post

Interpret and validate customer structural requirements; develop load paths and support load synthesis from test, flight, or thermal data sources.

Support trade studies, ply schedule optimization, and material selection to meet performance and manufacturability constraints.

Collaborate with design engineering on case geometry, interface loads, and tooling support—participation in early design phases encouraged.

Author clear and technically sound analysis reports, stress notes, and presentation materials for internal and external stakeholders.

Contribute to root cause investigations, failure analyses, and process improvements involving composite case integrity or structural margins.

Support broader stress analysis tasks, including metallic component modeling, fracture mechanics, and thermal-structural evaluations, as needed.

Provides guidance, coaching and training to others across the team when needed.

Works continually to improve upon existing processes or establish new systems.

Must be able to obtain a Security Clearance

Qualifications:

Bachelor’s Degree and minimum 9 years of prior relevant Structural Engineering experience.

Graduate Degree and a minimum of 7 years of prior related Structural Engineering experience.

In lieu of a degree, minimum of 13 years of prior related Structural Engineering experience.

Preferred Additional Skills:

Experience with high performance solid rocket motor composite case analysis is highly desirable.

Deep understanding of composite mechanics, including classical lamination theory, micromechanics, shear lag, rule of mixtures, and orthotropic material behavior.

Demonstrated expertise in composite structural modeling using ANSYS Mechanical APDL and ANSYS Composite PrepPost (ACP).

Proven ability to model filament-wound pressure vessels and overwrapped hardware in thermomechanical load environments.

Experience interpreting and applying aerospace structural requirements, including margin of safety development and strength knockdown factors.

Ability to collaborate with design engineering to support ply schedule development, tooling interaction, and manufacturability reviews.

Strong foundation in conventional stress analysis techniques (metallic structures, fracture mechanics, buckling) is a plus.

Effective communicator with the ability to produce detailed technical documentation and present findings to internal and external stakeholders.

Proficiency with Microsoft Office tools and strong technical writing skills