Aerospace Design Engineer

Role Overview
We are seeking a motivated and capable Aerospace/Mechanical Design Engineer with 2–6 years of industry experience to contribute to the design, analysis, and manufacturing of primary and secondary aerospace structural and mechanical systems. The ideal candidate will bring a mix of hands-on design experience, technical proficiency, and curiosity for learning in fast-paced environments. This is a hands-on technical role with opportunities for increased project ownership and mentoring responsibilities over time.

Key Responsibilities

• Contribute to the preliminary and detailed design of composite and metallic aerospace structures
• Perform CAD-based layout and modeling of structural and mechanical systems
• Support rapid prototyping and hands-on fabrication of early-stage designs
• Conduct basic structural analyses using hand calculations
• Prepare and release engineering drawings and documentation for manufacturing
• Collaborate cross-functionally with analysis, manufacturing, and test teams
• Maintain strong organizational and communication skills to track task progress and support project execution
• Demonstrate ownership of assigned tasks and show initiative in problem-solving

Minimum Qualifications

• U.S. Person as defined by ITAR (Citizen or Permanent Resident)
• Bachelor’s degree in Aerospace, Mechanical, or related Engineering field from an accredited university
• 2–6 years of relevant experience in aerospace structural or mechanical design
• Experience designing or supporting aerospace vehicle structures (aircraft or spacecraft)
• Familiarity with composite materials (carbon/fiberglass) and/or machined metallic structures
• Proficiency with CAD software (e.g., SolidWorks, CATIA, or Siemens NX)
• Working knowledge of aerospace fasteners, bearings, and hardware selection
• Ability to perform basic static and kinematic analysis
• Strong written and verbal communication skills
• Proficiency with Microsoft Office 365 (Excel, Word, Outlook, PowerPoint)

Preferred Qualifications

• Hands-on experience in prototype assembly or lab/shop environments
• Exposure to model-based definition and GD&T per ASME Y14.5
• Familiarity with FAA or MIL-STD requirements and certification standards
• Experience collaborating with manufacturing or test teams

Benefits

• 401(k) with company matching
• Medical, dental, and vision insurance
• Health savings account
• Flexible work schedules
• Paid time off and Comp Time
• Annual Bonus

Location Requirements/Working Conditions

• Onsite presence required at Sterling, VA office
• Occasional travel may be required for project support
• Work is performed in both an office and shop environment which requires proper safety precautions. Work may require physical effort in handling boxes, power tools, materials, prototypes, and various equipment. Occasional fieldwork may be required. You may need to lift up to 50 lbs.

About SDA (Structures.aero)
Structures.aero (SDA) provides engineering services to a diverse range of aerospace customers that create versatile vehicles from hand-launched drones to manned spacecraft and everything in between. Our core expertise lies in advanced composite structures, supported by a strong background in metallic structures. We engage across the full product lifecycle, taking the lead or providing critical support from early design through production, and are growing to meet rising demand for our capabilities.

SDA is an Equal Employment Opportunity Employer. We prohibit discrimination and harassment of any kind based on protected characteristics as outlined by federal, state, and local laws.

Job Type: Full-time

Benefits:

• 401(k)
• 401(k) matching
• Dental insurance
• Flexible schedule
• Health insurance
• Health savings account
• Paid time off
• Vision insurance

Schedule:

• 8 hour shift
• Day shift
• Monday to Friday

Education:

• Bachelor's (Required)

Ability to Commute:

• Sterling, VA 20166 (Required)

Work Location: In person