Composites Design Engineer

Founded in 2022, Mach Industries is a rapidly growing defense technology company focused on developing next-generation autonomous defense platforms. At the core of our mission is the commitment to delivering scalable, decentralized defense systems that enhance the strategic capabilities of the United States and its allies. With a workforce of approximately 220 employees, we operate with startup agility and ambition.

Our vision is to redefine the future of warfare through cutting-edge manufacturing, innovation at speed, and unwavering focus on national security. We are dedicated to solving the next generation of warfare with lethal systems that deter kinetic conflict and protect global security.

Mach is seeking a Composites Design Engineer to support the design, analysis, and testing of composite structures for our next-generation autonomous vehicles. At Mach, we exist to build platforms that maintain an allied American edge. As a key member of our team, you will contribute to the development of lightweight, high-performance composite airframe structures that meet the demands of modern defense technology. The role will involve designing composite components, performing structural analysis, supporting hands-on fabrication and testing, and developing solutions that are optimized not only for performance, but also for scalable, high-volume production.

• Design and develop composite structures for unmanned aerial vehicles (UAVs), supporting lightweight, high-performance airframe solutions from concept through flight test.

• Own composite components across the full development cycle — including laminate design, structural analysis, fabrication support, and validation testing.

• Perform structural analysis using hand calculations and FEA to evaluate stiffness, strength, stability, and failure modes.

• Collaborate with manufacturing and test teams to translate designs into buildable hardware and validate performance through testing.

• Participate in hands-on fabrication and integration of prototype composite hardware.

• Support structural test planning and execution, helping correlate analytical predictions with physical test results.

• Develop laminate architectures, joints, and structural concepts that are optimized not only for performance, but also for repeatability and scalability in higher-volume production.

• 7+ years of experience designing and/or building composite structures.

• Bachelor’s degree or higher in Mechanical Engineering, Aerospace Engineering, Materials Engineering, or a related field.

• Proficiency with NX or similar CAD tools.

• Experience performing FEA using tools such as ANSYS or similar simulation software.

• Comfortable working across design, analysis, and test of structural hardware.

• Experience with laminate design and composite structural analysis (CLT and/or FEA).

• Hands-on experience with composite manufacturing processes such as prepreg layup, vacuum bagging, infusion, or bonded assemblies.

• Rapid prototyping tools and or parts.

• Experience with aerospace or UAV composite structures (wings, fuselages, control surfaces, etc.).

• Experience with autoclave and out of autoclave prepreg thermoplastic and thermoset composites, RTM, filament winding, chopped fiber press molding, automated processing such as automated fiber placement (AFP) and or automated tape laying (ATL).

• Understanding of manufacturing-driven design tradeoffs (ply drops, minimum radii, bridging, fiber steering constraints).

• History of defining inspection and NDI methods (ultrasound, CT, thermography).

• Work using Fibersim for laminate definition and manufacturing planning.

• Familiarity with composite failure modes such as delamination, buckling, and fatigue.

• Time spent supporting structural testing and analysis correlation.

• Comfort working in a lab or shop environment including trimming, bonding, and basic composite repair.

Disclosures

This position may require access to information protected under U.S. export control laws and regulations, including the Export Administration Regulations (EAR) and the International Traffic in Arms Regulations (ITAR).  Please note that any offer for employment may be conditioned on authorization to receive software or technology controlled under these U.S. export control laws and regulations without sponsorship for an export license.

Mach participates in E-Verify and will provide the federal government with your Form I-9 information to confirm that you are authorized to work in the U.S.

The salary range for this role is an estimate based on a wide range of compensation factors, inclusive of base salary only. Actual salary offers may vary based on (but not limited to) work experience, education and training, critical skills, and business considerations. Highly competitive equity grants are included in most offers and are considered part of Mach’s total compensation package. Mach offers benefits such as health insurance, retirement plans, and opportunities for professional development.

Mach is an equal opportunity employer committed to creating a diverse and inclusive workplace. All qualified applicants will be treated with respect and receive equal consideration for employment without regard to race, color, creed, religion, sex, gender identity, sexual orientation, national origin, disability, uniform service, Veteran status, age, or any other protected characteristic per federal, state, or local law, including those with a criminal history, in a manner consistent with the requirements of applicable state and local laws. If you’d like to defend the American way of life, please reach out!