Mechanical Engineer - Composite Structures

Company: DART Aerospace

Location: Kirkland, Quebec, Canada – On-site

Department: Engineering

Employment Type: Full-Time, Permanent

Reports to: Engineering Manager

Shape the Next Generation of Rotorcraft Mission Equipment

DART Aerospace is a global aerospace company specializing in the design, manufacturing, and certification of mission-critical equipment and solutions for the helicopter and aerospace industry.

We are looking for an experienced Senior Mechanical Engineer – Composite Structures to join our Montreal engineering team.

In this role, you will take technical ownership of the design, development, integration, and sustainment of mechanical systems and composite structures for rotorcraft mission equipment. You will work across the complete product lifecycle, collaborating with engineering, manufacturing, certification, suppliers, and test teams to deliver lightweight, high-strength and manufacturable aerospace solutions.

This position is suited to an engineer who combines solid composite structural design expertise with a practical understanding of how aerospace products are manufactured, tested, certified, and supported in service.

What You’ll Do

Design & Engineering

- Design and develop mechanical systems and composite structures for rotorcraft mission equipment.
- Create and maintain 3D CAD models, engineering drawings, installation layouts, and product definitions using SolidWorks or equivalent CAD software .
- Perform structural sizing, tolerance analysis, and engineering trade studies.
- Evaluate vibration, fatigue, crashworthiness, thermal loading, weight, and operational constraints specific to rotorcraft applications.
- Develop composite solutions using materials such as carbon fiber, fiberglass, aramid, honeycomb sandwich panels, and structural adhesives.

Structural Analysis & Integration

- Collaborate with stress engineers to substantiate composite structures through FEA, static strength, fatigue, damage tolerance, and vibration assessments.
- Support the integration of mission equipment into aircraft while considering interfaces, accessibility, maintainability, wiring and harness routing, cooling, and weight and balance.
- Apply GD&T; principles and tolerance stack-up analysis to ensure robust product definition and assembly.

Manufacturing & Production Support

- Work closely with Manufacturing and suppliers to optimize composite fabrication methods, tooling, assembly processes, and repairability.
- Support manufacturing processes including prepreg layup, autoclave curing, vacuum bagging, resin infusion, trimming, bonding, and final assembly.
- Investigate manufacturing non-conformances and in-service issues.




- Lead or contribute to root-cause analysis and implementation of effective corrective actions.

Testing, Certification & Product Lifecycle

- Support prototype builds, ground testing, environmental qualification, vibration testing, EMC verification, and flight test activities.
- Participate in design reviews, configuration management, Material Review Boards (MRBs), and certification activities.
- Develop and maintain engineering documentation including specifications, Interface Control Documents (ICDs), ECRs, ECOs, installation instructions, and Bills of Materials.
- Ensure designs comply with customer requirements and applicable civil or military rotorcraft airworthiness requirements.

What We’re Looking For

Required Qualifications

- Bachelor’s degree in Mechanical Engineering, Aerospace Engineering , or a related engineering discipline.
- 5+ years of aerospace structural design experience , preferably involving rotorcraft mission equipment.
- Demonstrated experience designing composite aerospace structures and bonded assemblies .
- Strong knowledge of composite materials including carbon fiber, fiberglass, aramid, honeycomb structures, and structural adhesives.
- Proficiency with SolidWorks, Siemens NX, or equivalent CAD software .
- Strong understanding of GD&T; (ASME Y14.5) and tolerance stack-up analysis.
- Knowledge of composite manufacturing processes.
- Experience with structural analysis methods and exposure to FEA tools such as MSC Nastran, ANSYS, HyperMesh, or Abaqus .
- Strong understanding of aerospace materials, fasteners, inserts, and bonded-joint design.
- Strong analytical, problem-solving, technical documentation, and communication skills.

Strong Assets

- Knowledge of rotorcraft vibration environments and structural dynamics.
- Familiarity with FAA Part 27/29 or EASA CS-27/29 requirements.
- Understanding of environmental qualification requirements such as RTCA DO-160 or military equivalents.
- Experience supporting aerospace qualification, certification, or flight-test programs.
- Working knowledge of AS9100 quality management systems.

What Success Looks Like You combine deep technical expertise with practical engineering judgment.

You can take ownership of complex mechanical and composite design challenges, make technically sound decisions, and work effectively across Engineering, Manufacturing, Quality, suppliers, and certification teams.





You understand that successful aerospace engineering goes beyond CAD: designs must be structurally sound, manufacturable, testable, certifiable, maintainable, and reliable in demanding operating environments.

Why Join DART Aerospace?

- Work directly on specialized rotorcraft mission equipment used in demanding operational environments.
- Take technical ownership of challenging mechanical and composite engineering projects.
- Work across the full product lifecycle — from concept and design through manufacturing, testing, certification, and in-service support.
- Collaborate with multidisciplinary engineering and manufacturing teams within a global aerospace organization.
- Apply and deepen your expertise in composite structures, rotorcraft integration, and aerospace product development.

Ready to take ownership of complex aerospace engineering challenges? Apply today and join DART Aerospace’s engineering team.

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Contribuez à la prochaine génération d’équipements de mission pour hélicoptères

Nous recherchons un(e) Ingénieur(e) mécanique senior – Structures composites pour rejoindre notre équipe d’ingénierie à Montréal.

Dans ce rôle, vous prendrez en charge la conception, le développement, l’intégration et le soutien technique de systèmes mécaniques et de structures composites destinés aux équipements de mission pour hélicoptères.

Vous interviendrez sur l’ensemble du cycle de vie des produits, en collaboration avec les équipes d’ingénierie, de production, de certification, les fournisseurs et les équipes d’essais.

Profil recherché

Qualifications requises

- Baccalauréat en génie mécanique, génie aérospatial ou discipline connexe.
- Minimum de 5 ans d’expérience en conception structurale aéronautique , idéalement dans le domaine des équipements de mission pour hélicoptères.
- Expérience démontrée en conception de structures composites aéronautiques et assemblages collés .
- Excellente connaissance des matériaux composites : fibre de carbone, fibre de verre, aramide, structures sandwich en nid d’abeille et adhésifs structuraux.
- Maîtrise de SolidWorks, Siemens NX ou logiciel CAO équivalent .
- Bonne maîtrise du GD&T; (ASME Y14.5) et des analyses de chaînes de tolérances.
- Bonne connaissance des procédés de fabrication composite.
- Expérience avec les méthodes d’analyse structurale et connaissance d’outils FEA tels que MSC Nastran, ANSYS, HyperMesh ou Abaqus .
- Bonne compréhension des matériaux aéronautiques, fixations, inserts et assemblages collés.
- Excellentes capacités d’analyse, de résolution de problèmes, de communication et de documentation technique.

📌 Mechanical Engineer (Kirkland)
🏢 Dart Aerospace
📍 Kirkland