Senior Design Engineer

Senior/Staff Design Engineer (Hypersonics, Weapons, Rocket, Missile, Solid Rocket)

Required Skills & Experience

• Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, or a related field with 7+ years of relevant experience.

• Experience designing rocket motors, solid propulsion hardware, primary structures, motor cases, mechanisms, components, and/or assemblies.

• Strong solid/structural mechanics and engineering fundamentals, including thermodynamics and fluid dynamics.

• Experience taking hardware from clean-sheet design through manufacturing, assembly, testing, and qualification.

• Experience with CAD and engineering analysis tools; specific software packages are not required.

• Strong understanding of metal additive manufacturing, including design, material, and process limitations.

• Ability to collaborate across engineering, manufacturing, testing, supply chain, and customer teams.

• Understanding of insensitive munitions principles related to solid rocket motor design.

• Must be eligible to obtain and maintain a Secret security clearance.

Nice to Have Skills & Experience

• Master’s degree or PhD in Mechanical Engineering, Aerospace Engineering, or another relevant technical discipline.

• Experience conducting insensitive munitions testing and product qualification.

• Hands-on experience supporting rapid product development.

• Experience designing hardware and manufacturing processes for high-rate production and automation.

• Experience with composite overwrap and filament winding design and analysis.

• Experience with Siemens NX, Ansys, or similar engineering software.

• Active DoD Secret clearance or higher.

Job Description

Insight Global's client is looking for a Staff Design Engineer. The Staff Design Engineer will own the design, analysis, development, and qualification of solid rocket motor primary structures, including motor cases, mechanical components, mechanisms, assemblies, secondary structures, and related propulsion systems. This role requires a strong background in solid mechanics and the ability to take hardware from clean-sheet design through manufacturing, assembly, testing, qualification, and production. Additive manufacturing is a significant part of the product strategy, so this individual should have strong experience designing metal hardware for additive manufacturing and an understanding of emerging manufacturing technologies. The ideal candidate will also have experience designing hardware and manufacturing processes for high-rate production, automation, scalability, and reduced touch labor.

Key Responsibilities:

• Own clean-sheet design and development of solid rocket motor hardware, including motor cases, mechanisms, structural components, and assemblies.

• Apply solid mechanics and structural engineering principles from component-level design through integrated systems.

• Translate customer and internal requirements into reliable, cost-effective designs.

• Design hardware for additive manufacturing, high-rate production, automation, and reduced touch labor.

• Lead design development from concept through prototype manufacturing, assembly, testing, and qualification.

• Review test results, troubleshoot hardware, and implement design changes as needed.

• Develop and maintain aggressive but achievable product schedules while identifying and mitigating design risks.

• Provide engineering dispositions for discrepant or nonconforming hardware, including supporting analysis as needed.

• Create and approve CAD models, drawings, and engineering documentation in accordance with internal requirements and ASME Y14.5-2009.

• Collaborate across engineering, manufacturing, testing, procurement, and supply chain to address design, production, and technical risks.

• Provide technical mentorship and help establish engineering design best practices.