Aerospace Structural Design Engineer

Expleo Group USA is seeking experienced Aerospace Structural Design Engineer (remote) to support current aerospace programs focused on aircraft structural design, module development, composite and metallic airframe design, product development, and manufacturing support.

• Design and develop aircraft modules, structural assemblies, and components.
• Create innovative design solutions that meet performance, manufacturability, weight, quality, and cost objectives.
• Develop detailed layouts and assemblies for composite and aluminum aircraft structures.
• Support airframe integration and subsystem packaging activities.
• Collaborate with cross-functional engineering teams to ensure successful design implementation from concept through production.
• Evaluate design concepts and recommend improvements to enhance structural performance, reliability, and manufacturability.

• Develop detailed 3D CAD models, assemblies, and engineering drawings utilizing SolidWorks.
• Create and release production-ready engineering documentation.
• Manage design revisions and engineering change activities throughout the product lifecycle.
• Maintain CAD and engineering data in accordance with company, customer, and aerospace standards.
• Generate Bills of Materials (BOMs) and support configuration management processes.
• Ensure design documentation is accurate, complete, and aligned with program requirements.

• Create detailed manufacturing drawings utilizing ASME Y14.5 GD&T standards.
• Define critical dimensions, tolerances, and inspection requirements.
• Support Manufacturing and Quality teams in interpreting and applying engineering requirements.
• Review designs and drawings for compliance with aerospace engineering standards and customer requirements.
• Drive design improvements that simplify manufacturing, assembly, and inspection processes.
• Ensure proper application of geometric dimensioning and tolerancing principles throughout product development.

• Lead and participate in Design Failure Mode and Effects Analysis (DFMEA) activities.
• Identify potential design risks and implement mitigation strategies early in the development cycle.
• Support verification, qualification, and validation testing activities.
• Perform root cause investigations and implement corrective design actions when required.
• Collaborate with Manufacturing and Quality teams to resolve product performance and reliability issues.
• Support continuous improvement efforts focused on product quality and engineering excellence.

• Partner closely with Manufacturing Engineering teams to ensure designs support efficient production processes.
• Support prototype builds, testing activities, and production ramp-up efforts.
• Evaluate supplier-produced components and assist with resolution of design-related issues.
• Drive continuous improvement initiatives related to design quality, product performance, and manufacturability.
• Support engineering change implementation and ongoing product development activities.

• Bachelor's Degree in Mechanical Engineering, Aerospace Engineering, or a related engineering discipline.
• Equivalent combination of education and significant aerospace design experience may be considered.
• 8+ years of aerospace structural design, product development, or aircraft engineering experience.
• Advanced proficiency in SolidWorks 3D modeling, assemblies, and drawing creation.
• Strong expertise in GD&T and aerospace engineering drawing development.
• Experience conducting and facilitating DFMEA activities.
• Hands-on experience designing composite and aluminum aircraft structures.
• Strong understanding of structural design principles, mechanical systems, and manufacturability requirements.
• Experience supporting prototype development, testing, and production release activities.
• Excellent analytical, problem-solving, and communication skills.
• Ability to work effectively within multidisciplinary engineering teams.
• Experience supporting Unmanned Aerial Systems (UAS), UAVs, or autonomous aircraft programs.
• Familiarity with Airbus engineering processes, standards, and documentation requirements.
• Experience with composite fabrication techniques and aerospace assembly methods.
• Background in lightweight aircraft structure design and optimization.
• Experience supporting aerospace certification, testing, and structural validation activities.
• Knowledge of aerospace configuration management and change control processes.
• Understanding of stress analysis principles and structural design requirements.
• Experience working in fast-paced aerospace product development environments.
• Experience supporting prototype, low-rate production, or sustainment programs.