> Markdown version of [/jobs/ext/3578735-structures-design-engineer-staff-senior](https://www.wearedevelopers.com/jobs/ext/3578735-structures-design-engineer-staff-senior). Every page supports `.md` or `Accept: text/markdown`. Links point to the HTML versions so they work for humans too. Agent guide: [/agents.md](https://www.wearedevelopers.com/agents.md).

---

# Structures Design Engineer- Staff/Senior

- **Company:** Aurora Flight Sciences
- **Location:** Manassas, VA, United States
- **Experience:** Expert
- **Salary:** $92,000.0 - $164,000.0
- **Contract:** Permanent contract
- **Skills:** Microsoft Word, Microsoft Excel, 3d Models, Computer-Aided Design, Microsoft Office, Microsoft PowerPoint, Siemens NX, CATIA V5, Generative AI, Enovia, Smarteam
- **Published:** October 4, 2026
- **Apply:** https://diversityjobs.com/main/sendform/8/8/28176/1/16661080?backUrl=%2Fcareer%2F16661080%2FStructures-Designer-Staff-Senior-Virginia-Manassas

## About the Role

Ability to obtain a US Security Clearance for which the US Government requires US Citizenship.
-Bachelor's Degree in Mechanical Engineering, Aerospace Engineering, or a related discipline.
-Minimum of 5 years of experience in aerospace or related fields.
-Competence with CAD software, particularly CATIA V5, SmarTeam, or similar product data management systems (e.g., Enovia LCA or PDM).
-Knowledge of industry standards relating to composite component design, manufacturing, repair, and assembly (specific to aerospace).
-Proficiency with Microsoft Office 365 (Excel, Word, and PowerPoint).
-Strong verbal and written communication skills with a collaborative mindset.
Preferred Requirements

-Expertise in CATIA V5 modules, including Generative Surface Design, Part Design, and Assembly (experience with Unigraphics or Siemens NX will be considered).
-Advanced knowledge of composite material structures, including design, stacking sequences, lamination theory, bonded assemblies, and post-cure machining operations.
-Familiarity with prototype and rate production, including exposure to manufacturing tooling design, planning, and hands-on fabrication.
-Geometric Dimensioning and Tolerancing (GD&T): Knowledge of ASME Y14.5 and related tolerance analysis techniques.
-Experience with Model-Based Definition (MBD): Familiarity with ASME Y14.41 methods and CATIA V5 FTA for functional tolerancing and annotations.
-Strong foundation in manufacturing and development of aerospace structural components and assemblies.
Physical Requirements

-Ability to work on-site on a weekly basis at our Manassas, VA or Cambridge, MA locations.

## Description

At Aurora Flight Sciences, we design, build, and fly advanced aircraft and enabling technologies from concept to reality. We are searching for a talented and self-motivated Structures Design Engineer- Staff/Senior to help us create the future of flight. Responsibilities will include but not be limited to the following:
Responsibilities

Technical Leadership:
-Provide the first line of technical authority within the design team, with responsibility for approving design concepts and determining technical objectives for projects.
-Lead by example, mentoring and guiding junior engineers while working independently for extended periods.

Design and Development:
-Create airframe structural configuration layouts and detailed designs, including preliminary sizing, joint layouts, and interface boundary definitions for parts and assemblies, working with both metallic and composite materials.
-Develop and maintain CAD models and drawings of installations, assemblies, and detail components, ensuring strict adherence to structural integrity, interface boundaries, weight, and cost targets.
-Conduct design reviews and validate product structures to ensure components meet functional, fit, and form requirements.

Project Execution:
-Assume ownership of project execution and integration, leading teams of engineers to deliver against program budgets and deadlines.
-Coordinate with stress, manufacturing, procurement, and quality control teams to mature designs from initial conception to full-scale production.
-Track weekly progress and maintain project documentation to ensure alignment with program milestones.

Cross-Functional Collaboration:
-Collaborate effectively with manufacturing and tooling teams for prototyping, material selection, and production strategies, particularly for composite components.
-Prepare and present technical and programmatic data during Preliminary Design Reviews (PDRs) and Critical Design Reviews (CDRs).

Mentorship and Training:
-Offer technical guidance and mentorship to team members, including junior designers, to achieve high-quality deliverables.