Senior Mechanical Engineer - Composite Structures

Rotorcraft Mission Equipment

Company: DART Aerospace

Employment Type: Full-time, Permanent

Build Mission-Critical Aerospace Solutions

DART Aerospace is a global leader in the design and manufacture of mission-critical equipment and certified solutions for the helicopter and aerospace industry.

We are looking for a Senior Mechanical Engineer – Composite Structures to provide technical leadership in the design, development, integration and certification of advanced structural solutions for rotorcraft mission equipment.

This is a senior, hands-on engineering role for someone who can take ownership of complex products from concept through certification, production and in-service support , while providing technical guidance to other engineers.

What You’ll Do

Lead Composite Structural Design

Lead the design and development of composite structures and mechanical systems for rotorcraft mission equipment.

Develop structural concepts optimized for weight, strength, durability, manufacturability, maintainability and lifecycle cost .

Define composite laminate architectures, bonded joints, sandwich panel constructions and structural interfaces.

Lead technical trade studies, design reviews and key engineering decisions.

Own the Product Lifecycle

Take technical ownership from conceptual design through qualification, certification, production and fleet sustainment .

Oversee detailed CAD models, engineering drawings, installation packages and product definition using SolidWorks or equivalent CAD software .

Manage engineering changes, including ECRs, ECOs and configuration documentation.

Support Analysis & Certification





Work closely with stress analysts on FEA, fatigue, damage tolerance, vibration, thermal and crashworthiness assessments .

Support certification activities and compliance documentation.

Contribute to qualification, environmental, vibration, EMC and flight testing programs.

Drive Cross-Functional Integration

Collaborate with Systems Engineering, Avionics, Electrical, Manufacturing, Quality, Flight Test, Certification and Supply Chain .

Work directly with manufacturing teams and suppliers to improve composite fabrication, tooling, assembly, quality and repairability.

Investigate design issues, manufacturing non-conformances and in-service failures through structured root cause analysis.

Provide Technical Leadership

Act as a technical authority for composite structural design within assigned programs.

Mentor junior and intermediate engineers.

Establish engineering best practices and conduct technical reviews.

Represent Engineering in customer meetings, certification discussions, design reviews and technical audits.

What We’re Looking For

Required Qualifications

Bachelor’s degree in Mechanical Engineering, Aerospace Engineering or a related discipline .

8–12+ years of aerospace engineering experience .

Significant experience in composite structural design and integration .





Demonstrated experience taking aerospace structures through the complete product lifecycle .

Strong expertise in

Composite materials and laminate design

Bonded structures and joints

Structural interfaces

Lightweight structural optimization

Advanced proficiency with SolidWorks or equivalent CAD software .

Solid knowledge of GD&T; / ASME Y14.5 and tolerance analysis.

Experience collaborating with structural analysis teams using tools such as MSC Nastran, ANSYS, Abaqus or HyperMesh .

Strong understanding of aerospace composite manufacturing processes, including tooling, bonding, curing, inspection and repair .

Strong technical leadership, analytical, communication and project coordination skills.

Preferred Experience

Experience in one or more of the following would be a strong asset:

Rotorcraft or helicopter mission equipment

Rotorcraft vibration environments and structural dynamics

FAA Part 27/29 or EASA CS-27/29 certification

Military airworthiness requirements

AS9100 quality systems

Configuration management and design assurance

Supplier technical management

Multidisciplinary aerospace development programs

Why Join DART Aerospace?

You’ll work on specialized aerospace equipment used in demanding, mission-critical operations around the world.

This position offers the opportunity to combine hands-on engineering, technical ownership and leadership , while influencing products throughout their full lifecycle.

If you have deep composite structures expertise and want to take technical ownership of challenging aerospace programs, we want to hear from you.

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Structures sandwich

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