Company Description
DarkAero specializes in engineering aircraft optimized for speed, range, and efficiency. Our expertise in advanced materials, manufacturing, and aerodynamic design positions us uniquely to support demanding aerospace projects.
Role Description
This is a full-time role in Madison, WI for a Manufacturing Engineer. The Manufacturing Engineer will work closely with the engineering team to design and develop composite structures and components that meet specific aerospace requirements. The responsibilities of this role include, but are not limited to, performing design analysis, creating product drawings, and conducting evaluations to help maintain the quality of design and manufacturing. The position requires an attention to detail, accuracy, and an ability to work in a fast-paced environment.
Responsibilities
- Design of primary and secondary composite structures for advanced manned and unmanned aircraft
- Design complex composite parts, laminate & core schemes, bonded assemblies, metallic inserts, patterns, and tools
- Develop design criteria where definition is lacking
- Perform hand calculations and simulations to develop, assess, and optimize designs
- Design for manufacturability, optimize for development speed, mass, cost, and supervise first article builds
- Participate in vehicle system design and development
- Design and execute qualification testing
Qualifications
- Bachelor's degree in Aerospace Engineering, Mechanical Engineering, or a related field
- Experience in designing, modeling, or manufacturing composite structures for aircraft, spacecraft, or other high performance vehicles
- Experience with 3D modeling software such as Onshape, CATIA, SolidWorks, or similar CAD software
- Strong understanding of composite material properties, manufacturing processes, and tools
- Ability to conduct material testing and analysis of results using standard aerospace testing methods
- Familiarity with aerospace and regulatory standards, such as FAA certification requirements
- Excellent communication skills and the ability to work well in a team environment
Skills and Experience Preferred
- Demonstrated ability to manufacture composite components
- Demonstrated understanding of structural analysis and failure modes of complex mechanical systems
- Experience in selecting materials and manufacturing methods for mechanical components
- Highly self-motivated with strong organizational, written, and oral communication skills
- Solid understanding and application of GD&T
- Ability to work long hours and weekends if necessary
- Experience with finite element analysis (FEA) and failure analysis
ITAR REQUIREMENTS
To conform to U.S. Government export regulations, applicant must be a (i) U.S. citizen or national, (ii) U.S. lawful, permanent resident, (iii) Refugee under 8 U.S.C. § 1157, or (iv) Asylee under 8 U.S.C. § 1158, or be eligible to obtain the required authorizations from the U.S. Department of State.