Sr Specialist, Structural Engineering

Job Title: Sr Specialist, Structural Engineer

Job Code: 33382

Job Location: Huntsville, AL 

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

Job Description:

In this role, you will perform structural analysis to verify product designs meet structural performance requirements and assist with preliminary design verification. This role requires an experienced structural engineer with a strong technical foundation in aerospace structures, particularly rocket propulsion, a proactive mindset, and a passion for solving problems that can be but are not typically complex in high-performance environments.

As a key contributor, you will manage and/or 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.  Work will be performed under general oversight.

Why This Role Matters:
You won’t be just running models - you’ll be influencing major design decisions and contributing directly to flight-critical hardware. This position is a unique opportunity to work on cutting-edge propulsion technologies that drive national defense initiatives.

Essential Functions:

• Structural Analysis Ownership: Drive analysis tasks for SRM components including metallic and composite motor cases, nozzles, insulation, and propellant grains. Ensure structural integrity across all phases of flight and ground handling.
• FEA Modeling & Execution: Build and execute finite element models using ANSYS, ABAQUS, or comparable tools. Model components using isotropic, orthotropic, and viscoelastic material definitions with nonlinear and temperature-dependent properties.
• Load Development: Collaborate with thermal, CFD, and performance teams to establish pressure, thermal gradient, and mechanical loading conditions. In some cases, derive boundary conditions and load cases based on mission and design requirements.
• Closed-Form Support: Apply classical methods to validate and supplement numerical results, especially for preliminary design trades or quick-turn assessments.
• CAD & Geometry Integration: Import and simplify solid CAD models from design teams to develop robust, clean geometry suitable for analysis.
• Margin of Safety Evaluation: Determine margins of safety against yield, ultimate failure, buckling, HCF, LCF, and fracture using established industry standard practices and internal allowables.
• Documentation & Reporting: Produce high-quality technical reports, stress notes, and presentations that clearly outline methods, assumptions, and conclusions for both internal reviews and external customer delivery.
• Design Integration: Participate in formal and informal design reviews. Communicate results, trade-offs, and risk areas effectively to multidisciplinary audiences, including program management and external customers.
• Process Improvement: Contribute to internal tool development, analysis automation, and knowledge capture to enhance team efficiency and standardization.
• Ability to obtain a US Security Clearance.

Qualifications:

• Bachelor’s Degree and minimum 6 years of prior structural analysis experience. Graduate Degree and a minimum of 4 years of prior structural analysis experience. In lieu of a degree, minimum of 10 years of prior structural analysis experience.

Preferred Additional Skills:

• Bachelor’s Degree (in Mechanical, Aerospace, or related Engineering discipline) is preferred.
• Master’s degree preferred.
• Proven experience in linear, nonlinear, and dynamic structural analysis supporting design and qualification of solid rocket motors.
• Proficiency with FEA tools such as ANSYS Mechanical; experience with ANSYS MAPDL or Python scripting is highly desirable.
• Familiarity with structural assessment and design of filament-wound composite pressure vessels is a strong asset.
• Demonstrated ability to interpret aerospace structural requirements and coordinate load development with cross-functional teams.
• Working knowledge of structural instabilities, material nonlinearities, and coupled load environments.
• Exposure to full lifecycle aerospace SRM propulsion product development, from design through manufacturing and test.
• Strong technical communication skills and proficiency with Microsoft Office (Word, Excel, PowerPoint).

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