Aerospace Structural Design Engineer

Overview

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

Responsibilities:

Aircraft Structure & Module Design

• 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.

3D Modeling & Engineering Documentation

• 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.

GD&T & Technical Drawings

• 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.

DFMEA & Design Validation

• 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.

Manufacturing & Program Support

• 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.

Qualifications:

• 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.

What We Offer

At Expleo Group USA, we value expertise, innovation, and collaboration. By joining our client's team, you'll contribute to cutting-edge aerospace programs while working alongside industry-leading engineering professionals in a highly technical and collaborative environment.

• Competitive Compensation – Up to $120,000 annually or $58/hourly. Final compensation will be determined based on the role, skill alignment, years of experience, and fair, market-based rates by geography.
• Comprehensive Benefits for You and Your Dependents – Extensive Medical Plans, Dental, Vision, HSA with company contribution, company-sponsored Life Insurance and Short/Long-Term Disability Insurance, a host of voluntary plans including legal, hospital, accident, pet wellness, and 401(k) with matching.
• Paid Holidays and Paid Time Off
• Career Development and Advancement – Expleo is a global company operating in 29 countries with a strong focus on professional development.
• Strong Team Culture – Collaborate with experienced professionals who value technical excellence, innovation, and teamwork.

This position may require access to information subject to U.S. export control regulations (e.g., ITAR/EAR). Employment is contingent upon the ability to obtain such access. Under these regulations, access may be limited to "U.S. Persons," including U.S. citizens, lawful permanent residents (green card holders), and individuals granted refugee or asylee status.

Expleo is a trusted partner for end-to-end, integrated engineering, quality services, and management consulting for digital transformation. We are a talent incubator. The time you spend at Expleo will turbocharge your career, allowing you to work on complex technical challenges, expand your skills, and participate in inspiring multidisciplinary collaborations. Whether working on unmanned aircraft systems, advanced aerospace structures, or next-generation engineering solutions, you'll have the opportunity to become a bolder version of yourself. Let's change the game together.

Expleo is an equal opportunity employer. We are committed to non-discrimination in all stages of the recruitment process, ensuring fair and unbiased hiring practices. We evaluate qualified applicants without regard to race, color, religion, sex (including pregnancy), sexual orientation, gender identity, national origin, age, disability, genetic information, or any other protected characteristic under applicable laws.

Benefits

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