Senior Design Engineer

Insight Global · Berthoud, United States

About the Role

Our client is seeking a Senior Design Engineer to support the design, analysis, development, and qualification of solid rocket motor hardware and propulsion systems. This individual will own hardware throughout the full product lifecycle, from clean-sheet design through manufacturing, testing, qualification, and production.

This role is ideal for an engineer with a strong mechanical or aerospace background, experience with propulsion or structural hardware, and a passion for developing innovative products in a fast-paced environment.

Responsibilities

• Design and develop solid rocket motor hardware, including motor cases, structures, mechanisms, and assemblies.
• Perform mechanical and structural analyses to support product performance and reliability.
• Lead projects from concept through manufacturing, testing, qualification, and production.
• Design components for additive manufacturing, automation, and scalable production.
• Review test data, troubleshoot issues, and implement design improvements.
• Create and maintain CAD models, drawings, and engineering documentation.
• Collaborate with engineering, manufacturing, testing, supply chain, and customer teams.

Required Qualifications

• Bachelor's degree in Mechanical Engineering, Aerospace Engineering, or related field.
• 5+ years of relevant engineering experience.
• Experience designing rocket motors, propulsion hardware, motor cases, structures, mechanisms, or similar aerospace systems.
• Strong knowledge of solid mechanics, structural mechanics, thermodynamics, and fluid dynamics.
• Experience taking hardware from concept through production.
• Experience with CAD and engineering analysis tools.
• Strong understanding of metal additive manufacturing principles.
• Understanding of insensitive munitions requirements.
• Ability to obtain and maintain a DoD Secret Clearance.

Preferred Qualifications

• Master's degree or PhD in a related engineering discipline.
• Experience with insensitive munitions testing and qualification.
• Experience with rapid product development or high-rate manufacturing.
• Composite overwrap or filament winding experience.
• Experience with Siemens NX, ANSYS, or similar software.
• Active DoD Secret Clearance or higher.

If you're excited about designing next-generation propulsion systems and working on mission-critical aerospace and defense programs, we'd love to hear from you.