Find & Apply For Aerospace Engineer Jobs in Florence, Texas

Overview Frontera Space is developing a next-generation space transportation vehicle and is seeking a Responsible Engineer (RE) to own its composite airframe structural systems. The Airframe Structures RE will be the technical owner and primary point of accountability for the architecture, design, analysis, materials, manufacturing, test, and qualification of the vehicle's primary and secondary airframe structures. This position will work in concert with the Pressurized Structures RE and will own the complete non-pressurized composite airframe, including its structural integration with the vehicle's Thermal Protection System (TPS). This is a hands-on technical leadership position. The RE will establish the airframe structural architecture, make fundamental materials and design decisions, build and lead the airframe structures team, and maintain end-to-end technical integrity from early development through flight. The ideal candidate combines deep experience in lightweight composite aerospace structures with a fundamental understanding of composite mechanics, structural stability, bonded and mechanically fastened joints, damage tolerance, fracture mechanics, manufacturing processes, and structural durability under combined mechanical and thermal environments. Experience integrating composite structures with high-temperature systems or Thermal Protection Systems is highly desirable. This is a full-time, exempt, in-person position reporting to the Structures Division Director in the Austin, Texas area. What You'll Do Serve as the Responsible Engineer and technical authority for composite airframe structures on Frontera's next-generation space transportation vehicle. Architect the complete composite airframe structural system, including skins, spars, ribs, frames, bulkheads, control surfaces, fairings, aerodynamic surfaces, structural joints, attachments, interfaces, and supporting secondary structure. Own requirements development, structural architecture, preliminary sizing, detailed design, analysis, manufacturing development, test, qualification, and flight implementation. Establish material systems, laminate architectures, structural concepts, load paths, joints, interfaces, and manufacturing approaches. Own the structural integration of the airframe with pressurized structures, propulsion systems, landing systems, control systems, payload systems, and other major vehicle subsystems. Work directly with the Pressurized Structures RE to establish compatible interfaces and vehicle-level load paths between pressure structures and the surrounding airframe. Lead the development of lightweight airframe structures subjected to combined: Aerodynamic loads Maneuver and inertial loads Landing and ground loads Propulsion loads Acoustic and vibration environments Thermal gradients Localized high-temperature environments Manufacturing and cure-induced residual stresses Repeated flight and operational cycling Understand and control the fundamental mechanisms governing composite structural durability, including: Fiber and matrix failure Matrix microcracking Delamination Bonded-joint failure Fastener-bearing and bypass failure Mode I and Mode II fracture Structural buckling Thermal-expansion mismatch Cure shrinkage and residual stresses Fatigue and accumulated damage Impact damage and damage tolerance Develop lightweight structural arrangements capable of efficiently transferring aerodynamic, propulsion, landing, payload, and subsystem loads throughout the vehicle. Own the structural aspects of TPS integration, including: TPS attachment architecture TPS-to-structure interfaces Thermal expansion accommodation Thermal gradients introduced into primary structure Local reinforcement and load transfer Inspection and maintainability Repeated-flight durability Partner with thermal and TPS engineers to ensure the airframe remains structurally capable throughout ascent, atmospheric flight, reentry, landing, and repeated reuse. Perform and/or direct structural analysis including: Composite laminate stresses and margins Global vehicle structural analysis Local detailed stress analysis Buckling and structural stability Bonded and mechanically fastened joints Fracture mechanics Damage tolerance Fatigue and structural life Thermal-structural interaction Cure-induced and thermally induced stresses Nonlinear structural behavior where required Develop material characterization and structural verification programs spanning coupons, elements, subcomponents, development articles, major structural assemblies, and full-scale vehicle structures. Define and execute static, fatigue, buckling, thermal-structural, joint, damage-tolerance, and qualification testing. Correlate analytical models with test results and use test data to mature structural designs and material models. Work directly with manufacturing engineers and technicians to establish robust, repeatable composite fabrication and assembly processes. Establish design allowables, structural margins, factors of safety, acceptance criteria, inspection requirements, and verification methodologies. Lead technical and design reviews for airframe structural systems. Own technical disposition of structural nonconformances, manufacturing deviations, damage, and test anomalies. Partner closely with pressurized structures, aerodynamics, loads and dynamics, TPS, thermal, propulsion, landing systems, manufacturing, test, and systems engineering. Recruit, mentor, and lead the engineering team responsible for composite airframe structures. Establish the tools, analysis methods, standards, and engineering practices required to rapidly develop flight-critical composite structures. Drive designs toward minimum mass, high structural efficiency, manufacturability, durability, rapid production, inspectability, repairability, and operational reliability. What Success Looks Like You become the technical owner of the composite airframe structural architecture for Frontera's next-generation space transportation vehicle. You establish a technically rigorous approach to designing a lightweight, highly integrated composite airframe capable of reliably carrying demanding aerodynamic, mechanical, landing, propulsion, and thermal loads. You develop an airframe architecture that integrates effectively with Frontera's pressurized structures and Thermal Protection System while enabling efficient manufacturing, inspection, maintenance, and repeated flight. You build and lead a highly capable engineering team while remaining directly involved in the critical structural, materials, manufacturing, analysis, and test decisions. You lead the system from structural architecture and material/process development through component testing, full-scale structural qualification, and ultimately flight-ready hardware. Employment Details Full-time, exempt position Primarily in-person at Frontera Space in Austin, Texas Regular interaction with engineering, manufacturing, integration, and test teams Travel to suppliers, manufacturing facilities, and test locations may be required Hands-on participation in hardware development and structural testing is expected Qualifications What We're Looking For (Requirements) Bachelor's degree in Aerospace Engineering, Mechanical Engineering, Materials Engineering, or a related technical discipline. 4+ years of professional experience directly developing composite aerospace airframe or primary structural systems. Demonstrated experience with composite aircraft structures, launch vehicle structures, spacecraft structures, control surfaces, aerodynamic structures, or comparable flight-critical hardware. Strong fundamental understanding of composite mechanics, laminate theory, structural analysis, and composite failure mechanisms. Strong understanding of structural load paths, buckling, stability, bonded joints, mechanically fastened joints, and lightweight structural design.

Fundamental understanding of:

Composite laminate mechanics Fiber and matrix failure Matrix microcracking Delamination Bonded-joint behavior Fracture mechanics Damage tolerance Fatigue Structural buckling Thermal stresses Cure-induced residual stresses Permeability of composite pressure structures Experience with structural proof, qualification, or development testing of pressure hardware. Experience working directly with composite manufacturing and flight or production hardware. Ability to independently make and defend critical technical decisions for flight-critical structures. Demonstrated ability to lead multidisciplinary engineering efforts and develop other engineers. Bonus Points (Preferred) 10+ years of experience developing composite aerospace airframe or primary structures. Prior experience as a Responsible Engineer, Principal Engineer, Lead Engineer, or equivalent technical authority for a major aircraft, launch vehicle, spacecraft, missile, or flight structural system. Experience architecting a clean-sheet airframe structural system from initial concept through qualification and flight. Demonstrated experience building and leading an engineering team responsible for a major vehicle subsystem. Deep expertise in carbon-fiber composite primary structures. Experience developing large integrated composite airframe structures. Experience with highly optimized thin-gauge composite skins, stiffened structures, spars, ribs, frames, bulkheads, sandwich structures, or control surfaces. Deep understanding of the relationship between: Material system Laminate architecture Manufacturing process Cure cycle Thermal expansion Residual stress Structural stability Microcracking Fracture toughness Fatigue Damage tolerance Experience designing and qualifying bonded primary structures. Experience with AFP/ATL, prepreg layup, resin infusion, bonded structures, co-cured structures, sandwich structures, or automated composite manufacturing. Experience developing test programs from material coupons through full-scale structural qualification. Experience with Thermal Protection Systems or high-temperature structural integration. Experience designing TPS attachment systems and managing differential thermal expansion between TPS and primary structure. Experience with reusable aerospace structures and repeated-flight structural life management. Experience on launch vehicles, spacecraft, reusable space vehicles, hypersonic vehicles, missiles, high-performance aircraft, or other advanced aerospace systems. Technical Skills Composite laminate design and analysis Primary airframe structural design Composite failure criteria and damage mechanics Global and local finite element analysis Structural buckling and stability Bonded-joint design and analysis Mechanically fastened composite joints Fracture mechanics and damage tolerance Mode I and Mode II fracture behavior Composite fatigue and durability Thermal-structural analysis Residual stress analysis Structural load-path development Structural dynamics and load interaction Material characterization and test correlation Composite manufacturing processes Structural test planning and execution Full-scale structural qualification TPS structural integration Engineering requirements and verification Design review and technical authority Working Conditions This role operates in a fast-paced aerospace development environment spanning office engineering, manufacturing, integration, and test activities. The position may involve work around large composite structures, pressure systems, cryogenic systems, test equipment, manufacturing machinery, and flight hardware. The successful candidate must be comfortable moving between analytical models, first-principles engineering calculations, CAD and drawings, physical hardware, and hands-on structural testing. Export Control Eligibility Certain positions supported by this role may involve work subject to U.S. export-control laws and regulations. Candidates for those roles may be required to meet applicable U.S. export-control eligibility requirements. Equal Opportunity Employer Frontera Space is an equal opportunity employer. We are committed to providing a workplace free from discrimination and harassment and consider applicants without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, age, disability, veteran status, genetic information Why Join Us? Join Frontera Space at an early stage and help create a transformational aerospace platform designed to change how high-speed aircraft and access-to-space systems are developed, manufactured, and operated. You will have the opportunity to influence the vehicle architecture, solve foundational technical challenges, and see your work move rapidly from analysis and design into hardware, testing, and flight. As an early team member, you will take on broad ownership, help establish the engineering culture, and directly shape both the product and the company. Frontera Space offers meaningful equity participation and the chance to create lasting value while working on technology with the potential to redefine aerospace performance, affordability, and operational capability. This is an opportunity to do more than contribute to an established program—it is a chance to help build the vehicle, the team, and the company from the ground up.

Pay:

$98,568.00 - $147,852.00 per year

Benefits:

401(k) Dental insurance Health insurance Vision insurance

Work Location:

In person