Senior Composite Engineer (R0165007) (J)

Aerodyne Industries is a dynamic, rapidly growing engineering and information technology services firm headquartered on Florida’s exciting Space Coast. With locations throughout the US, we take pride in delivering small business agility with large corporation capabilities. Our list of clients count on us to prepare NASA’s Missions to the Moon and Mars and to defend our nation supporting the Missile Defense Agency and Department of Defense. Join the adventure of a lifetime by becoming a teammate with Aerodyne Industries and work on projects that will define our future.

Position Overview This role supports composite structures design, analysis, and manufacturing for NASA Marshall Space Flight Center (MSFC) programs. The engineer will work on composite components for launch vehicles, propulsion systems, and spacecraft structures. This position is ideal for a strong composites engineer looking to grow into MSFC-specific requirements and advanced spaceflight applications. Must be a US citizen and have a STAR ID.

Key Responsibilities

Composite Design & Analysis

• Perform design and analysis of composite components for aerospace structures.
• Develop laminate schedules, evaluate material behavior, and assess structural performance under mechanical and thermal loads.
• Support FEA modeling activities including linear and basic non-linear analysis, buckling checks, and failure assessments.
• Participate in trade studies and support requirements development.

Program Support & Collaboration

• Work directly with MSFC engineering teams, suppliers, and other contractors to develop composite solutions.
• Support design reviews (PDR, CDR) by preparing presentation materials and technical documentation.
• Contribute to testing plans, NDI evaluation, and verification activities as needed.

Manufacturing & Materials

• Support composite fabrication activities including autoclave layup, AFP/ATL, and resin infusion processes.
• Participate in tooling reviews, process development, and troubleshooting of manufacturing issues.
• Assist with material evaluation, process documentation, and coordination with manufacturing engineering.

Testing & Verification

• Support composite component testing, data review, and correlation activities.
• Assist with structural test planning, failure investigation activities, and corrective action discussions.

General Responsibilities

• Maintain configuration, documentation, and compliance with engineering processes.
• Communicate effectively across disciplines and contribute to a collaborative team environment.

Required Qualifications
Bachelor’s degree in aerospace, mechanical, materials engineering, or related field.

• 10–15+ years of experience working with composite materials and structural components (aerospace preferred).
• Experience with composite laminate design, basic FEA, and mechanical/thermal load assessment.
• Hands-on familiarity with composite manufacturing processes such as autoclave layup, AFP/ATL, or RTM/VARTM.
• Proficiency in CAD and FEA tools (CATIA, NX, SolidWorks, Abaqus, ANSYS, or Nastran).
• Ability to work within structured engineering processes and deliver high‑quality technical documentation.

Preferred (Nice-to-Have) Qualifications

• Experience supporting spaceflight, launch vehicle, or defense composite structures.
• Exposure to cryogenic composites, pressure vessels, or large‑scale aerospace structures.
• Familiarity with NASA/MSFC standards or similar government requirements.
• Experience with NDI methods such as UT, thermography, or X‑ray.
• Scripting or automation experience (Python, MATLAB).

Essential Functions

Work Environment:

Office environment. Requires ability to provide clear, concise, accurate and timely communication, both verbally and in writing (100%). Requires ability to interact professionally with co-workers, management, and client (100%). Requires travel in the domestic USA (5%). Requires ability to work at a computer for long periods of time (100%).

Physical Requirements:

Requires sitting for extended periods of time in meetings with peers, management, and with our client at NASA facilities to discuss technical issues (10%). Also, requires sitting for extended periods of time at a desk to write reports and perform engineering tasks (80%). Requires ability to use stairs or elevators for access between floors and multiple buildings at NASA and our facilities (10%).

Equipment and Machines:

Requires ability to operate a personal computer, a telephone, fax machine, copier, calculator, and other general office equipment (100%).

Attendance:

Normal workday 7:30-4:30, Monday thru Friday. Minimal overtime may be required (10%) to meet schedule milestones and to support technical demands of the job. Regular attendance is a necessity, and adequate arrangements for delegating duties during absences are required.

Other Essential Functions:

The ability to work independently with minimal supervision, and to make rational decisions, and to exercise good judgment is essential (100%). Grooming and dress must be appropriate for the position and must not impose a safety risk/hazard to the employee or others.

Proof of U.S. Citizenship is required.

All qualified applicants will receive consideration for employment without regard to race, color, sex, sexual orientation, gender identity, religion, national origin, disability, veteran status, age, marital status, pregnancy, genetic information, or other legally protected status.

Final compensation is determined through a comprehensive evaluation of several key factors, including the candidate’s educational background, specialized technical expertise, and relevant professional experience. We also consider internal equity, prevailing market data, and specific contractual or funding requirements to ensure competitive and equitable offer alignment.

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