Structural Engineer - Composite & Product Design

Job Summary
We are seeking a Composite Structural Engineer to support the design, development, analysis, testing, and manufacturing of structural products in a fast-paced engineering environment. The ideal candidate will have strong experience with SolidWorks, product design, GD&T, DFMEA, FEA, DFM, material selection, and product testing, along with hands-on manufacturing and troubleshooting capabilities. This role will work closely with cross-functional engineering and manufacturing teams to develop innovative, cost-effective products, evaluate failure modes, perform structural analysis, conduct functional testing, and drive projects from concept through completion. Experience with sheet metal, plastics, casting, composites, and Value Engineering/VAVE is highly desirable.

Key Responsibilities

• Design and develop composite/structural products from concept through production.
• Create and modify 2D drawings and 3D models using SolidWorks.
• Perform tolerance stack-up, GD&T, DFMEA, and FEA analysis.
• Apply engineering principles, hand calculations, and handbook methods to product design and analysis.
• Develop designs using sheet metal, plastics, casting, and other manufacturing processes.
• Select appropriate metal and polymer materials based on product requirements.
• Build prototypes and test samples for product validation.
• Develop test procedures and conduct functional and performance testing.
• Analyze test results and correlate findings with product performance.
• Identify and evaluate failure modes, failure margins, and potential design risks.
• Troubleshoot product and manufacturing issues and recommend corrective actions.
• Support Value Engineering/VAVE and cost-reduction initiatives.
• Work closely with manufacturing and cross-functional engineering teams.
• Manage projects independently from initial concept through completion.
• Prepare technical documentation, reports, spreadsheets, and databases.
• Support a fast-paced manufacturing environment and travel up to 10% overnight as required.

Required Skills

• Product Design & Development
• Composite/Structural Engineering
• SolidWorks
• 2D Drawing & 3D Modeling
• PDM
• GD&T
• Tolerance Stack-Up
• DFMEA
• FEA
• DFM
• Product Testing & Validation
• Failure Mode & Failure Analysis
• Hand Calculations
• Material Selection
• Sheet Metal
• Plastics/Plastic Molding
• Casting
• Manufacturing Processes
• Value Engineering (VAVE)
• Cost Reduction & Costing
• Prototype/Test Sample Development
• Test Equipment Operation
• Microsoft Excel, Word & Outlook
• Problem Solving & Root Cause Analysis
• Project Management
• Cross-Functional Collaboration
• Strong Written & Verbal Communication

Education
Bachelor's degree in Mechanical Engineering, Structural Engineering, Materials Engineering, Composite Engineering, or a related engineering field preferred.
Equivalent combination of relevant engineering education and hands-on product design/manufacturing experience may be considered.
Practical experience with product design, structural analysis, manufacturing, and testing is highly preferred.