Spacecraft Structures Engineer

Department: Engineering

Location: Ashburn, VA

Employment Type: FullTime

Space Structures Engineer

Overview Energy is turning uninterrupted sunlight in space into directable energy on Earth. From our homebase in Virginia, we’re building satellites that will deliver energy from orbit to the grid and make solar a reliable 24/7 resource.

Overview Energy’s Structures Engineer leads the design, structural analysis, testing, and manufacturing of spacecraft structural systems from concept through integration and flight. The role blends hands-on engineering with technical leadership, driving the creation and implementation of structural assemblies, components, and integrated systems. The ideal candidate brings proven expertise in spacecraft structures including both analytical and hands-on disciplines, thrives in a fast-paced, multidisciplinary environment, and takes ownership from initial concept through full system integration. You will collaborate closely with design, test, manufacturing, and systems engineering teams to ensure designs meet mission requirements, reliability standards, and production readiness.

Responsibilities:

• Lead end-to-end development, analysis, prototyping, and integration of structural systems and spacecraft components for advanced space systems, collaborating closely within a cross-functional engineering team

• Perform comprehensive structural analysis of spacecraft and platform components, including composites and metallic structures, using advanced analytical methods and industry-standard software (NX Nastran, FEA tools)

• Develop, refine, and validate finite element models to assess structural performance under static, dynamic, thermal, and acoustic loads; perform trade studies and mass optimization analyses

• Develop allowables and assess structural margins for bolted and bonded joints

• Design and model parts, assemblies, and components in CAD software (NX), ensuring manufacturability, ease of assembly, and complete product definition including drawings, GD&T specifications, and test procedures

• Apply design-for-manufacturing (DFM) principles and rapid prototyping techniques to optimize spacecraft designs for simplicity, reduced cost, and efficient production

• Define, process, and interpret static and dynamic ground test and flight data, including sensor selection, data validation, and environment determination (random vibration, shock, quasi-static, acoustic, pressure, and thermal)

• Create documentation of analysis, test results and lessons learned

Requirements:

• Bachelor's degree in Mechanical, Aerospace, Structural Engineering, or equivalent hands-on experience in a mechanical/aerospace engineering role

• Minimum of 5-7 years of progressive experience in mechanical design, analysis, and testing

• Strong proficiency with 3D CAD software (NX preferred) and advanced FEA tools (NX Nastran or equivalent)

• Experience in spacecraft-level structural test campaign design, execution, data processing, and validation

• Solid understanding of GD&T, design-for-manufacturing (DFM) principles, and mechanical design best practices

• Strong understanding of dynamic mechanical system design, analysis, and failure modes (modal, random vibration, buckling, thermoelastic analysis)

• Demonstrated experience with structural analysis of both metallic and composite structures (laminate design, joint design, materials characterization)

• Experience with rapid prototyping and hands-on mechanical assembly

• Proven ability to own and deliver complex structural systems from concept through final implementation

• U.S. citizenship is required due to program requirements and ITAR compliance

Nice to have experience:

• Experience with sensor selection and data post-processing/interpretation (accelerometers, strain gauges, thermocouples, etc.)

• Hands-on experience with advanced manufacturing techniques including CNC machining, composite fabrication, additive manufacturing, and other precision fabrication processes

• Experience with spacecraft separation systems and related integration or testing activities

• Experience analyzing additive manufactured parts and nonlinear analysis (large displacement, metal plasticity)

• Experience with fatigue life analysis

• Experience defining and documenting procedures for satellite environmental testing, as well as processing and interpreting complex test data

• Master's in Mechanical, Aerospace, or Space Systems Engineering

• Ability to mentor junior engineers and lead technical initiatives

Benefits:

The health and safety of our employees and their families comes first. In addition to competitive salary and equity, we offer medical, dental, vision, disability, and life insurance coverage, a health and wellness stipend, 6 weeks of paid time off, parental leave, and employer 401K matching. The Company reserves the right to modify or change these benefits at any time.

ITAR Requirements:

To comply with U.S. Government space technology export regulations, including the International Traffic in Arms Regulations (ITAR), you must be a U.S. citizen, lawful permanent resident, protected individual as defined by 8 U.S.C. 1324b(a)(3), or eligible to obtain the required authorizations from the U.S. Department of State.

Equal Opportunity Employer:

Overview Energy is an Equal Opportunity Employer. Employment with Overview Energy is based on merit, competence, and qualifications, and is not influenced by race, color, religion, gender, national origin, ethnicity, veteran status, disability status, age, sexual orientation, gender identity, marital status, or any other legally protected status.

If you require a reasonable accommodation to complete the application process, please contact our Human Resources team at [email protected].

Studies show that women and individuals from underrepresented groups often apply for jobs only if they meet all listed qualifications. We encourage anyone who believes they can succeed in this role to apply, even if they do not meet every qualification listed.