Senior Structural Analysis Engineer in Addison, Texas at Firehawk Aerospace Inc

About the Role
We are seeking a Structural Analysis Engineer with Composite background to join our engineering team. This role combines advanced structural analysis with hands-on knowledge of polymer composite manufacturing and design. The ideal candidate will bridge the gap between theoretical analysis and practical fabrication, ensuring our composite structures are optimized for both performance and manufacturability. Knowledge in high temperature composite material and having a dynamics analysis background is a plus.

Key Responsibilities
Perform structural analysis of composite components using finite element analysis (FEA) tools (ANSYS, Abaqus, NASTRAN, or similar)
Knowledge of classical laminate theory and composite hand calculation methods
Conduct stress analysis, failure prediction, and damage tolerance assessments for composite laminates and structures
Develop and validate composite layup schedules considering manufacturing constraints and structural requirements
Support design reviews with analysis-driven recommendations on fiber orientation, ply stacking sequences, and material selection
Collaborate with manufacturing teams to ensure designs are producible and address fabrication challenges
Perform trade studies comparing composite materials, processes, and configurations
Support testing programs including correlation of analytical models with test data
Generate technical reports, analysis documentation, and design justification packages
Support nonconformances during prototype, development and manufacturing trials
Interface with customers, suppliers, and cross-functional teams on composite structural requirements

Required Qualifications
Bachelor's degree in Aerospace Engineering, Mechanical Engineering, or related field
5+ years of experience in composite structural analysis
Proficiency with FEA software (ANSYS, Abaqus, NASTRAN, or equivalent)
Working knowledge of composite materials (carbon fiber, fiberglass, Kevlar) and manufacturing processes (hand layup, autoclave cure, filament winding, RTM)
Understanding of composite failure theories (Tsai-Wu, Tsai-Hill, Hashin, etc.)
Experience with composite design principles and laminate theory
Strong analytical and problem-solving skills
Excellent written and verbal communication abilities

Preferred Qualifications
Master's degree in relevant engineering discipline
10+ years of experience in composite structural analysis
Hands-on experience with composite fabrication or manufacturing engineering
Knowledge of aerospace or defense industry standards (MIL-HDBK-17, NCAMP, CMH-17)
Experience with composite design software (HyperSizer, ESAComp, Fibersim, or similar)
Familiarity with test methods (ASTM D3039, D3410, D5528, etc.)
Background in rocket motor cases, pressure vessels, or aerospace structures
Knowledge in high temperature composite material systems
Programming/scripting skills (Python, MATLAB) for analysis automation
Experience in mechanical dynamics, vibration analysis, shock response, and environmental loading principles.
Active security clearance or ability to obtain one

ITAR Requirements
To conform to U.S. Government space technology export regulations, including the International Traffic in Arms Regulations (ITAR), you must be a U.S. citizen, lawful permanent resident of the U.S., a protected individual as defined by 8 U.S.C. 1324b(a)(3), or eligible to obtain the required authorizations from the U.S. Department of State.
Work Environment and Physical Requirements
This position requires mobility across manufacturing, testing, machine shop, and outdoor test environments. Duties may include walking, climbing, lifting up to 25 pounds, and working in high-hazard areas with appropriate PPE. Personal protective equipment such as safety glasses, safety shoes, hearing protection, flame-resistant clothing, and respiratory protection may be required based on task demands. The role may involve varying work hours including early mornings, nights, or weekends to support operations or facility maintenance activities.
Security Clearance
May be required to obtain and maintain a U.S. Security Clearance at the appropriate level. Requires U.S. Citizenship and ability to meet federal requirements for access to sensitive information.
Benefits at Firehawk Aerospace
• 100% employer-paid medical premiums for employees and up to 75% for dependents on select plans
• Affordable dental and vision plans with extensive coverage
• Employee Assistance Program including counseling, legal services, and wellness resources
• Flexible 9/80 work schedule option
• On-site snacks and refreshments
• Mentorship opportunities and involvement in advanced aerospace projects

Firehawk Aerospace is an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to protected characteristics.