Job Description

Wright Patterson AFB,OH,US
Remote Work:
Job Number:
Aero-Structural Design and Manufacturing Engineer

The Opportunity: 

As an Aero-structural Design and Manufacturing Engineer, you know leading-edge design and high-quality materials and manufacturing are critical elements required in verifying aero-vehicle structural integrity throughout the product lifecycle.  At Booz Allen, you can use your engineering expertise to develop next-generation defense tools and technology. We need your skills and expertise in the design of metallic and composite aircraft components, coupons, and related tooling and test fixtures to support stress analysis and load prediction, structural life forecasting, and structural integrity analysis for new and innovative aerospace solutions that directly impact the warfighter.

As an engineer working in our prototype design team, you’ll provide expertise in evaluating new technologies, performing risk assessments, and improving the design of aerospace systems. Your experience in aero-vehicle design is key and makes you an integral part of delivering a client-focused solution.

Join us. The world can’t wait. 

You Have: 

  • 4+ years of experience with metallic and composite structural design, analysis, and fabrication
  • Experience with composite design software, such as AUTOCAD, UG, SolidWorks, CATIA, or Pro-Engineer
  • Experience with structural analysis using finite element methods and software tools such as ABAQUS, ANSYS, NASTRAN, PATRAN and MATLAB
  • Experience with Geometric Dimensioning and Tolerancing GDT per ANSI specifications
  • Knowledge of manufacturing and design techniques, procedures and practices with experience in composite fabrication, assembly and test
  • Knowledge of using basic machine shop equipment of drill presses, grinders, band saws, shears, hand layout tools, and machine shop tools and practices
  • Ability to lift and maneuver heavy objects and work in and all around large irregular shaped parts
  • Ability to obtain a security clearance
  • Bachelor's degree in Mechanical Engineering or Aerospace Engineering 

Nice If You Have: 

  • Experience with using probabilistic composite structure stress, buckling and vibrational analysis methods. hand calculations of Rourk and Bruhn
  • Experience with aircraft structural layout and sizing and aero-structural design using composite materials
  • Experience with design for manufacturing techniques and procedures
  • Experience with design and analysis of carbon fiber reinforced polymers, glass fiber reinforced plastics, discontinuous fiber composites, or ceramic matrix and high temperature composites a plus
  • Experience with design and analysis of ceramic matrix and high temperature composites and probabilistic methods a plus
  • Knowledge of composite-related nondestructive inspection, procedures, practices and test processes in engineering
  • Secret clearance
  • Master's degree in Mechanical Engineering or Aerospace Engineering


Applicants selected will be subject to a security investigation and may need to meet eligibility requirements for access to classified information. 

Create Your Career:

Grow With Us
Your growth matters to us—that’s why we offer a variety of ways for you to develop your career. With professional and leadership development opportunities like upskilling programs, tuition reimbursement, mentoring, and firm-sponsored networking, you can chart a unique and fulfilling career path on your own terms. 

A Place Where You Belong
Diverse perspectives cultivate collective ingenuity. Booz Allen’s culture of respect, equity, and opportunity means that, here, you are free to bring your whole self to work. With an array of business resource groups and other opportunities for connection, you’ll build your community in no time.

Support Your Well-Being
Our comprehensive benefits package includes wellness programs with HSA contributions, paid holidays, paid parental leave, a generous 401(k) match, and more. With these benefits, plus the option for flexible schedules and remote and hybrid locations, we’ll support you as you pursue a balanced, fulfilling life—at work and at home. 

Your Candidate Journey
At Booz Allen, we know our people are what propel us forward, and we value relationships most of all. Here, we’ve compiled a list of resources so you’ll know what to expect as we forge a connection with you during your journey as a candidate with us.


At Booz Allen, we celebrate your contributions, provide you with opportunities and choices, and support your total well-being. Our offerings include health, life, disability, financial, and retirement benefits, as well as paid leave, professional development, tuition assistance, work-life programs, and dependent care. Our recognition awards program acknowledges employees for exceptional performance and superior demonstration of our values. Full-time and part-time employees working at least 20 hours a week on a regular basis are eligible to participate in Booz Allen’s benefit programs. Individuals that do not meet the threshold are only eligible for select offerings, not inclusive of health benefits. We encourage you to learn more about our total benefits by visiting the Resource page on our Careers site and reviewing Our Employee Benefits page.

Salary at Booz Allen is determined by various factors, including but not limited to location, the individual’s particular combination of education, knowledge, skills, competencies, and experience, as well as contract-specific affordability and organizational requirements. The projected compensation range for this position is $81,800.00 to $186,000.00 (annualized USD). The estimate displayed represents the typical salary range for this position and is just one component of Booz Allen’s total compensation package for employees. This posting will close within 90 days from the Posting Date.

Work Model
Our people-first culture prioritizes the benefits of flexibility and collaboration, whether that happens in person or remotely.

  • If this position is listed as remote or hybrid, you’ll periodically work from a Booz Allen or client site facility.
  • If this position is listed as onsite, you’ll work with colleagues and clients in person, as needed for the specific role.

EEO Commitment

We’re an equal employment opportunity/affirmative action employer that empowers our people to fearlessly drive change – no matter their race, color, ethnicity, religion, sex (including pregnancy, childbirth, lactation, or related medical conditions), national origin, ancestry, age, marital status, sexual orientation, gender identity and expression, disability, veteran status, military or uniformed service member status, genetic information, or any other status protected by applicable federal, state, local, or international law.

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