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Key Responsibilities and Required Skills for Aerospace Design Engineer

💰 $80,000 - $140,000

AerospaceEngineeringDesignMechanicalSystems

🎯 Role Definition

An Aerospace Design Engineer is responsible for defining, modeling, analyzing, and delivering aircraft components, subsystems, and systems that meet stringent performance, safety, regulatory, cost, and producibility requirements. This role combines advanced CAD/CAE skills, systems thinking, materials knowledge (metals and composites), and applied engineering judgment to develop concept-to-production designs for manned or unmanned aerospace platforms. The ideal candidate drives technical decisions through formal engineering processes (requirements flow-down, design reviews, verification & validation), collaborates with manufacturing and suppliers, and supports certification activities (FAA/EASA or applicable authorities).

📈 Career Progression

Typical Career Path

Entry Point From:

  • Junior Mechanical / Aerospace Engineer
  • CAD/CAE Engineer or Design Technician
  • Systems or Test Engineer with 0–3 years of aerospace experience

Advancement To:

  • Senior Aerospace Design Engineer
  • Lead Design Engineer or Principal Engineer
  • Systems Architect or Engineering Manager
  • Certification / Compliance Lead or Technical Fellow

Lateral Moves:

  • Systems Engineering
  • Structural Test & Validation Engineer
  • Manufacturing / Process Engineering
  • Supplier Quality or Integration Engineering

Core Responsibilities

Primary Functions

  • Lead end-to-end mechanical and systems design of aircraft structures, flight control surfaces, propulsion interfaces, or avionics enclosures using 3D CAD (CATIA V5/3DEXPERIENCE, NX, SolidWorks) to generate producible geometry, assemblies, and release-quality drawings with full GD&T and tolerance specifications.
  • Translate system-level requirements and specifications into detailed component designs and interface definitions, ensuring requirements traceability through DOORS, Jama, or equivalent requirements management tools.
  • Perform structural analysis and validation using FEA tools (ANSYS, NASTRAN, Abaqus) to size components, predict stress, deformation, and fatigue life, and document assumptions, boundary conditions, and acceptance criteria in analysis reports.
  • Conduct aero-structural trade studies and collaborate with aerodynamicists to optimize weight, stiffness, and performance while maintaining manufacturability and cost targets; present results to cross-functional teams to support technical decision-making.
  • Develop and maintain Bills of Materials (BOMs), part numbers, and engineering change notices (ECNs) in PLM/ERP systems (Windchill, Teamcenter, ENOVIA) and coordinate configuration control with Manufacturing and Quality.
  • Create and execute verification and validation plans, including component test plans, structural test coupons, fatigue tests, and subsystem integration tests; analyze test data, compare against predictions, and revise models as required.
  • Prepare and lead formal design reviews (PDR/CDR/TRR/FDR) with clear agendas, review packages, risk registers, and action item tracking to ensure design maturity and readiness for production or certification milestones.
  • Define and drive Design for Manufacturing and Assembly (DFM/DFMA) improvements by working with manufacturing engineering to reduce part count, simplify tooling, and ensure compatibility with assembly processes (mechanical fastening, adhesive bonding, composite layup).
  • Lead supplier engineering and technical negotiations: develop supplier specifications, review supplier drawings and test data, support supplier audits, and manage supplier design feedback to ensure compliance with program requirements.
  • Support certification and compliance activities by generating compliance matrices, producing design substantiation packages for FAA/EASA/TC, and addressing regulatory certification questions during review cycles.
  • Perform materials selection and process specification for metals and composites, including laminate schedules, layup sequence, cure cycles, fastener selection, and surface treatments, ensuring structural and environmental performance.
  • Implement and maintain robust design verification documentation including DFMEA/DFR, tolerance stack-ups, risk mitigation plans, and safety-of-flight analyses in accordance with AS9100 and company quality procedures.
  • Create manufacturable prototypes and rapid iterations using in-house prototyping, subcontractors, or additive manufacturing; lead hands-on build support and fit-checks to validate form, fit, and function.
  • Support root cause analysis and corrective action when field issues or test anomalies occur; lead hardware rework direction, containment plans, corrective action reports (CARs), and design updates required for resolution.
  • Mentor and coach junior design engineers and interns by delegating tasks, reviewing models and reports, and providing technical feedback to accelerate team capability and knowledge transfer.
  • Drive cost reduction initiatives by analyzing component cost drivers, optimizing material usage, and recommending consolidation of parts and commonality across product lines.
  • Integrate electromechanical components and harnesses into mechanical designs while coordinating with electrical and avionics teams to resolve packaging, thermal, and EMI constraints.
  • Lead thermal, vibration, and environmental analyses and coordinate multi-physics CAE simulations to ensure compliance with operational envelopes and qualification standards.
  • Maintain project schedules and provide regular status updates on technical progress, risk exposure, and resource needs to Program Managers and stakeholders; escalate issues when schedule or performance targets are at risk.
  • Develop and maintain engineering standards, templates, and reusable CAD libraries to streamline future design efforts and maintain consistency across product suites.
  • Participate in cross-functional trade studies for mission planning, payload integration, and system-level optimization to support program proposals and customer-facing technical briefings.
  • Provide hands-on support during production ramp-up: create tooling and assembly instructions, support first article inspections (FAI), and resolve process capability gaps identified during initial manufacturing runs.
  • Ensure environmental, health and safety (EHS) and quality compliance for lab and shop activities, including safe handling of composite materials, chemical processes, and test stands.

Secondary Functions

  • Support ad-hoc technical data requests, develop engineering change packages, and respond to supplier technical inquiries to maintain program continuity.
  • Contribute to continuous improvement initiatives across engineering processes (CAD standards, model-based definition, PLM workflows) to shorten design cycles and improve data quality.
  • Collaborate with manufacturing, quality, supply chain, and program management to translate design intent into executable production plans and to resolve cross-functional impediments.
  • Participate in Agile or stage-gate project teams to refine project scope, prioritize features, and ensure engineering deliverables map to program milestones.
  • Provide occasional on-site support at supplier facilities, test labs, and customer locations for integration activities, troubleshooting, and acceptance testing.

Required Skills & Competencies

Hard Skills (Technical)

  • Advanced 3D CAD proficiency: CATIA V5/3DEXPERIENCE, Siemens NX, or SolidWorks for complex assemblies and drawing release.
  • Finite Element Analysis (FEA): ANSYS, Nastran, Abaqus — modal, static, fatigue, and nonlinear analysis capability.
  • Knowledge of aerodynamics fundamentals and experience collaborating with CFD teams or using simplified CFD tools for concept studies.
  • Strong background in composites and metallic structural design: laminate design, ply drop handling, fastener and adhesive joint design, and damage tolerance.
  • Experience with systems engineering tools (DOORS, Jama) and Model-Based Systems Engineering (MBSE) concepts.
  • GD&T and tolerance analysis skills including stack-up analysis to ensure fit and function in assemblies.
  • Experience with certification processes and regulatory frameworks (FAA, EASA, Transport Canada) and quality standards such as AS9100 and ISO 9001.
  • Proficiency with PLM/ERP systems for BOM management and configuration control (Windchill, Teamcenter, ENOVIA).
  • Knowledge of DFMEA, DVP&R (Design Verification Plan & Report), and formal verification methodologies.
  • Hands-on test planning, instrumentation, and data analysis experience; comfortable authoring test procedures and interpreting results.
  • Proficiency in engineering data tools and scripting (MATLAB, Python, Excel VBA) for analysis automation and design optimization.
  • Familiarity with manufacturing processes: CNC machining, sheet metal forming, composite layup (ATL/AFP), adhesive bonding, and heat-treatment processes.
  • Product lifecycle understanding from concept, prototyping, qualification, certification, to production release.
  • Experience with tolerance-sensitive mechanisms, bearings, and precision interfaces for flight-critical systems.

Soft Skills

  • Strong written and verbal communication skills for communicating design rationale, technical reports, and presentations to stakeholders and certification authorities.
  • Cross-functional collaboration and influence: proven ability to work with manufacturing, quality, avionics, and supply chain to drive solutions.
  • Problem solving and analytical thinking with a data-driven approach to decision making and root-cause analysis.
  • Project and time management skills: prioritization, meeting deadlines, and handling multiple concurrent engineering tasks.
  • Attention to detail and quality mindset to produce release-ready drawings, analysis reports, and verification artifacts.
  • Leadership and mentorship aptitude for developing junior engineers and fostering a high-performance team culture.
  • Adaptability and resilience in a fast-paced environment with shifting customer or program priorities.
  • Customer focus and commercial awareness to balance performance, cost, and schedule in design trade-offs.

Education & Experience

Educational Background

Minimum Education:

  • Bachelor of Science in Aerospace Engineering, Mechanical Engineering, or closely related engineering discipline.

Preferred Education:

  • Master of Science in Aerospace or Mechanical Engineering, or equivalent advanced degree with specialization in structures, aerodynamics, or systems engineering.
  • Certifications: Professional Engineer (PE) or relevant industry certifications (e.g., AS9100 Lead Auditor, ISO qualifications) are a plus.

Relevant Fields of Study:

  • Aerospace Engineering
  • Mechanical Engineering
  • Materials Science & Engineering
  • Systems Engineering
  • Structural Mechanics / Dynamics

Experience Requirements

Typical Experience Range:

  • 3–8 years of relevant aerospace design experience for mid-level roles; 8+ years for senior/principal levels.

Preferred:

  • Demonstrated track record designing flight-critical systems or structures, performing FEA validation, and supporting certification programs.
  • Experience working on full lifecycle projects from concept through certification and production ramp.
  • Prior experience with commercial or military aircraft, rotorcraft, UAVs, or space vehicle design is highly advantageous.
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