Structural Engineer UAV H/F

As a Structural Engineer at Alta Ares, you will design and analyze the composite structures of our interceptor airframes, including fuselage, wings, and internal load-bearing components. You will perform stress analysis using hand calculations and FEA, optimize structural weight, and support testing and validation. You will work closely with manufacturing partners and cross-functional teams to ensure designs are manufacturable and transition from prototype to production.

Responsibilities

• Design and analyze the primary and secondary composite structures of our interceptor airframes (fuselage, wings/control surfaces, internal load-bearing components)
• Perform structural and stress analysis combining hand calculations and finite element analysis (FEA) to justify margins under static, dynamic, and high-acceleration loads
• Define and document load paths, free-body diagrams, and failure modes for all major structural elements
• Own composite laminate design, layup schedules, and bonding/joining strategies for carbon fiber structures
• Aggressively optimize structural weight without compromising strength, given the platform's speed and maneuverability requirements
• Work with Aerodynamics and Propulsion teams to balance structural mass, CG, and vibration constraints against flight performance targets
• Evaluate design trade-offs between composite and metallic/CNC solutions where each makes sense
• Support structural, vibration, shock, and environmental qualification testing of airframe components and subassemblies
• Analyze test and flight data to identify failure modes, including:
• Fatigue and fracture
• CG shifts
• Vibration-induced damage
• Support fast structural repairs and troubleshooting during flight test campaigns
• Work directly with manufacturing partners and internal fabrication teams to ensure designs are manufacturable, repeatable, and cost-effective at scale
• Get hands-on with composite fabrication and bonding to understand how parts are actually built, not just how they're modeled
• Support the transition of airframe structures from prototype to serial production
• Work closely with Aerodynamics, Propulsion, and Manufacturing engineers to resolve cross-disciplinary design conflicts
• Communicate structural decisions and analysis clearly to non-structural stakeholders
• Contribute to design reviews and structural documentation standards as the team scales

Requirements

• Over 3 years of experience as a Structures Engineer, Stress Engineer, or Structural Analyst, ideally on aircraft, UAVs, or other flight vehicles
• Engineering degree in Aerospace Engineering, Mechanical Engineering, or a related field
• Strong foundation in classical stress analysis: free-body diagrams, load paths, hand calculation methods
• Practical experience with FEA tools (e.g. NX Nastran, FEMAP, ANSYS, Simcenter 3D, or equivalent)
• Solid understanding of composite materials, laminate design, and bonding/joining techniques for carbon fiber or fiberglass structures
• Proficiency in CAD tools for structural design (Siemens NX, CATIA, SolidWorks, or equivalent)
• Hands-on mindset and ability to work effectively with physical hardware, not just analysis in isolation
• Comfortable working in a fast-moving startup environment with tight timelines and evolving requirements
• Fluent in English

Nice to have

• Hands-on experience with composite fabrication (layup, vacuum bagging, curing)
• Familiarity with composite-specific CAD tools (e.g. Fibersim)
• Experience designing structures for high-speed, high-acceleration, or expendable/attritable aircraft (interceptors, target drones, munitions)
• A track record of taking a structure from concept to flight, not just to a design study
• Exposure to military or defense-grade qualification standards
• Experience in fast-paced or startup environments