Senior Structural Engineer, Design and Analysis

About Mach IndustriesFounded in 2023, Mach Industries is a rapidly growing defense technology company focused on developing next-generation autonomous defense platforms. At the core of our mission is the commitment to delivering scalable, decentralized defense systems that enhance the strategic capabilities of the United States and its allies. With a workforce of approximately 350 employees, we operate with startup agility and ambition.Our vision is to redefine the future of warfare through cutting-edge manufacturing, innovation at speed, and unwavering focus on national security. We are dedicated to solving the next generation of warfare with lethal systems that deter kinetic conflict and protect global security.The RoleMach is seeking a Senior Structural Engineer, Design and Analysis to support the design, analysis, and testing of composite structures for our next-generation autonomous vehicles. At Mach, we exist to build platforms that maintain an allied American edge. As a key member of our team, you will contribute to the development of lightweight, high-performance composite airframe structures that meet the demands of modern defense technology. The role will involve designing composite components, performing structural analysis, supporting hands-on fabrication and testing, and developing solutions that are optimized not only for performance, but also for scalable, high-volume production.Key Responsibilities• Develop structural concepts and architectures for new UAV and aircraft platforms, with emphasis on efficient load paths, lightweight design, manufacturability, and structural integration.• Develop, maintain, and mature vehicle-level global finite element models (GFEMs) to support structural sizing, stiffness evaluation, load distribution, and vehicle development.• Use GFEM results to actively influence structural layout, spar locations, bulkheads, frames, joints, interfaces, skin construction, and overall vehicle architecture.• Develop appropriate FEM idealizations using shell, beam, rigid, spring, mass, and solid elements while balancing model fidelity, computational efficiency, and engineering usefulness.• Define modeling assumptions, boundary conditions, structural interfaces, connections, material properties, and load application methods for vehicle-level structural models.• Perform structural analysis using hand calculations, classical methods, and FEA to evaluate strength, stiffness, stability, buckling, joint behavior, and structural failure modes.• Develop structural free-body diagrams and load paths to ensure analytical models accurately represent the physical behavior of the vehicle.• Translate GFEM loads and vehicle-level results into component-level design loads and detailed structural analyses.• Perform detailed sizing and analysis of metallic, composite, and hybrid structures including skins, spars, frames, bulkheads, fittings, joints, and bonded assemblies.• Develop laminate architectures and composite structural concepts using classical laminate theory, finite element analysis, and appropriate composite failure criteria.• Work directly with designers to iterate structural geometry based on analytical results rather than treating design and analysis as separate activities.• Review CAD designs for structural efficiency, load-path continuity, manufacturability, assembly considerations, and analytical assumptions.• Establish structural margins and clearly communicate critical load cases, failure modes, sensitivities, and design recommendations to engineering leadership and vehicle teams.• Support structural test planning, instrumentation definition, test execution, and correlation of analytical models with physical test results.• Update analytical models using test data, measured stiffness, mass properties, and flight-test results as vehicle maturity increases.• Support structural design reviews and provide technical justification for structural architecture, sizing methodology, modeling assumptions, and margins.• Develop and document analysis methods, modeling standards, assumptions, and best practices that can be reused across multiple vehicle programs.• Mentor junior engineers in structural design, finite element modeling, load-path development, and first-principles structural analysis.Required Qualifications • 7+ years of experience in aircraft, spacecraft, UAV, missile, or similarly lightweight structural design and analysis.• Bachelor’s degree or higher in Mechanical Engineering, Aerospace Engineering, Civil/Structural Engineering, or a related technical field.• Strong understanding of structural mechanics, free-body diagrams, load paths, stiffness, strength, stability, and buckling.• Demonstrated experience developing and using finite element models to influence structural design.• Experience developing aircraft- or vehicle-level finite element models, structural stick models, GFEMs, or similarly large structural models.• Proficiency with an industry-standard FEA solver such as MSC Nastran, Siemens NX Nastran, Simcenter Nastran, ANSYS, Abaqus, or equivalent.• Experience with FEM pre/post-processing tools such as FEMAP, Simcenter 3D, Patran, HyperMesh, HyperX or equivalent.• Experience developing FEMs using shell, beam, rigid, spring, mass, and solid element formulations.• Ability to perform structural sizing using both classical hand calculations and finite element methods.• Experience analyzing metallic and/or composite aerospace structures.• Experience developing and evaluating bolted, bonded, and mechanically fastened structural joints.• Ability to work closely with CAD designers and provide actionable geometry and structural recommendations based on analysis.• Proficiency with NX, CATIA, Creo, SolidWorks, or similar CAD software and the ability to interrogate and understand complex vehicle assemblies.• Experience defining structural load cases, constraints, interfaces, and appropriate modeling assumptions.• Comfortable working in a rapid-development environment where analysis maturity increases alongside the physical vehicle design.Preferred Qualifications • Experience developing GFEMs for complete aircraft, UAVs, launch vehicles, missiles, or other integrated aerospace vehicles.• Experience with MSC Nastran / Simcenter Nastran SOL 101, SOL 103, and SOL 105 or equivalent static, modal, and buckling analysis methods.• Experience extracting GFEM interface loads and developing detailed submodels or component-level analyses.• Experience with structural model condensation, rigid-body checks, model verification, mesh convergence, and FEM quality checks.• Understanding of aircraft loads development and the relationship between aerodynamics, inertia, propulsion, mass properties, and structural loads.• Familiarity with aeroelasticity, modal analysis, loads and dynamics, or flutter analysis and the role of the structural GFEM in these disciplines.• Experience correlating finite element models to static structural tests, ground vibration tests, strain-gage data, or flight-test measurements.• Experience with composite aircraft structures including wings, fuselages, control surfaces, spars, sandwich panels, and bonded assemblies.• Working knowledge of composite laminate theory, composite failure criteria, delamination, crippling, local buckling, global buckling, and fatigue.• Experience with Fibersim or similar composite laminate definition and manufacturing tools.• Understanding of manufacturing-driven structural design considerations including ply drops, minimum radii, bridging, fiber steering, machining, fastening, bonding, and assembly tolerances.• Experience developing reusable structural analysis methods, FEM modeling standards, or automated analysis workflows.• Python, MATLAB, or similar scripting experience for FEM preprocessing, post-processing, load manipulation, model checking, or engineering calculations.• Experience supporting preliminary and critical design reviews and presenting structural analysis to multidisciplinary engineering teams.Additional RequirementsAvailable to work extended hours and weekends as neededITAR RequirementsTo conform to U.S. Government export regulations, applicant must be a (i) U.S. citizen or national, (ii) U.S. lawful, permanent resident (aka green card holder), (iii) Refugee under 8 U.S.C. § 1157, or (iv) Asylee under 8 U.S.C. § 1158, or be eligible to obtain the required authorizations from the U.S. Department of State. Learn more about the ITAR here. Engineer$140,000—$180,000 USDAt Mach, we believe that compensation is more than just a paycheck. It's a comprehensive package designed to reward the time, skills, and expertise you bring to our team. We are committed to offering competitive compensation that is equitable, transparent, and aligned with market trends.Key Elements of Our Compensation Philosophy:Competitive Salaries: We continuously research market rates to ensure our salaries are competitive with those in our industry and geographic location.Performance-Based Incentives: Our bonus structure is tied to both individual and company performance, creating a win-win scenario that motivates our team members to excel.Equity Participation: We offer stock options or equity to employees, ensuring that you share in the success and growth of the company.Benefit Packages: Our benefits include healthcare, dental and vision plans, retirement savings, and paid time off, because we understand that your well-being extends beyond the office.Professional Development: We allocate funds for continuing education, training, and career growth.Transparency: We are committed to openness about our compensation tiers and how decisions are made, ensuring trust and mutual respect.By joining Mach, you’re not just accepting a job—you’re becoming a key part of a team that values your contributions and invests in your growth. Together, we aim to create a rewarding environment that sets the stage for long-term success.Data PrivacyTo view Mach Industries candidate data privacy policy, please visit .DisclosuresThis position may require access to information protected under U.S. export control laws and regulations, including the Export Administration Regulations (EAR) and the International Traffic in Arms Regulations (ITAR). Please note that any offer for employment may be conditioned on authorization to receive software or technology controlled under these U.S. export control laws and regulations without sponsorship for an export license.Mach participates in E-Verify and will provide the federal government with your Form I-9 information to confirm that you are authorized to work in the U.S.The salary range for this role is an estimate based on a wide range of compensation factors, inclusive of base salary only. Actual salary offers may vary based on (but not limited to) work experience, education and training, critical skills, and business considerations. Highly competitive equity grants are included in most offers and are considered part of Mach’s total compensation package. Mach offers benefits such as health insurance, retirement plans, and opportunities for professional development.Mach is an equal opportunity employer committed to creating a diverse and inclusive workplace. All qualified applicants will be treated with respect and receive equal consideration for employment without regard to race, color, creed, religion, sex, gender identity, sexual orientation, national origin, disability, uniform service, Veteran status, age, or any other protected characteristic per federal, state, or local law, including those with a criminal history, in a manner consistent with the requirements of applicable state and local laws. If you’d like to defend the American way of life, please reach out!