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Position Overview

A highly experienced composite structures expert responsible for supporting NASA Marshall Space Flight Center (MSFC) programs through leading advanced composite design and development activities for launch vehicle and propulsion systems. This contractor position provides technical leadership across mission-critical projects and serves as a subject matter expert (SME) for composite materials and structures in extreme aerospace environments. This role requires deep technical expertise in space-qualified composites, strategic thinking, and the ability to drive innovation in next-generation launch and propulsion systems while ensuring compliance with MSFC and NASA standards. Must be a US citizen and have a STAR ID.

Key Responsibilities

Technical Leadership:

• Serve as the technical authority and SME for composite materials, design, analysis, and manufacturing supporting MSFC programs
• Lead the development of complex composite structures for spacecraft structures primary and secondary structure, such as launch vehicles, propulsion systems, in-space stages, and lander systems
• Define technical approaches and design philosophies for composite programs aligned with MSFC mission requirements
• Drive innovation in composite materials, processes, and design methodologies for launch vehicle and propulsion applications
• Resolve the most challenging composite technical issues across multiple MSFC programs and projects
• Provide composite technical guidance and direction to engineering teams and subcontractors
• Champion best practices, lessons learned, and continuous improvement across composite programs
• Interface with MSFC civil servant engineers, technical authorities, program/project managers, and other contractor organizations at a senior technical level
• Support MSFC technology development initiatives and advanced concepts studies

Strategic Design and Analysis:

• Lead design of highly complex composite structures for launch vehicle environments (ascent loads, acoustic, vibration, thermal, cryogenic)
• Perform and oversee advanced structural analysis including non-linear, damage tolerance, fracture mechanics, and long-duration mission life prediction
• Develop novel composite solutions for challenging mission requirements:
  • Cryogenic propellant tanks and tank structures
  • Launch vehicle interstages, adapters, and fairings
  • Deployable structures for in-space applications
  • Composite cases for solid rocket motors
  • Thermal protection and insulation systems
  • High-temperature propulsion component structures
• Establish design criteria, requirements, and verification/validation approaches per MSFC systems engineering processes
• Conduct trade studies involving multiple disciplines (structures, thermal, materials, propulsion, manufacturing)
• Validate designs through comprehensive analysis, environmental testing, and test-analysis correlation
• Lead failure investigations and anomaly resolution with root cause analysis and corrective action implementation
• Support technology readiness level (TRL) advancement activities from concept through TRL 9

Program and Technical Management:

• Lead composite engineering activities for major MSFC programs including:
  • Space Launch System (SLS)
  • Human Landing System (HLS)
  • In-Space Propulsion systems
  • Advanced propulsion concepts
  • Commercial crew/cargo vehicle support
• Manage technical scope, schedules, budgets, and deliverables for composite work packages
• Coordinate with systems engineering, loads/dynamics, materials engineering, manufacturing engineering, quality, and safety teams
• Support proposal development for MSFC contracts with technical content, approaches, and cost estimates
• Prepare and present technical reviews (PDR, CDR, TRR, FRR, etc.) to MSFC review boards and technical authorities
• Participate in MSFC technical interchange meetings (TIMs), design working groups, and technical panels
• Represent the contractor organization at technical conferences and industry forums
• Ensure compliance with contract technical requirements and deliverables
• Support Program/Project Control Board activities and change request evaluations

Manufacturing and Production Excellence:

• Lead development and qualification of advanced manufacturing processes for space-qualified composites
• Oversee transition from technology development to flight production
• Provide technical oversight of composite subcontractors and suppliers
• Troubleshoot complex manufacturing issues and implement solutions
• Develop manufacturing specifications, process controls, and acceptance criteria per MSFC quality standards
• Review and approve first article inspection reports, manufacturing readiness reviews, and production readiness reviews
• Champion cost reduction initiatives while maintaining mission assurance and flight safety
• Support make-vs-buy decisions and source selection technical evaluation
• Interface with MSFC Manufacturing Engineering Laboratory (MEL) for process development support

Standards, Requirements, and Mission Assurance:

• Lead verification and validation activities for composite structures per MSFC and NASA requirements
• Ensure compliance with MSFC standards including:
  • MSFC-STD-3012 (Stress Analysis and Fracture Control Requirements for Spaceflight Hardware)
  • MSFC-SPEC-250 (Polymeric Materials, Non-Metallic)
  • MSFC fracture control and damage tolerance requirements
  • MSFC design and analysis guidelines
• Apply NASA standards:
  • NASA-STD-5001 (Structural Design and Test Factors of Safety)
  • NASA-STD-5019 (Fracture Control Requirements for Spaceflight Hardware)
  • NASA-STD-6016 (Standard Materials and Processes Requirements for Spacecraft)
  • NPR 7120 series (Systems Engineering Processes)
  • NPR 7123 (Systems Engineering Processes and Requirements)
• Ensure compliance with industry composite standards:
  • CMH-17 (Composite Materials Handbook)
  • ASTM composite test standards
  • SACMA recommended methods
  • ARP, MIL-HDBK, and other applicable specifications
• Support MSFC safety review processes and Safety Technical Review Boards (STRBs)
• Interface with MSFC Materials and Processes Laboratory for materials qualification support
• Support Materials Review Board (MRB) and configuration control processes
• Support certification of flight readiness for composite structures
• Interface with NASA Engineering and Safety Center (NESC) during independent assessments

Mentorship, Collaboration, and Knowledge Management:

• Mentor junior and mid-level engineers and contractor personnel in composite design and analysis
• Develop internal training materials and conduct technical workshops
• Build and develop composite engineering capabilities within the contractor organization
• Foster collaboration with MSFC civil servants, other contractors, and university partners
• Contribute to technical documentation, lessons learned databases, and design guidelines
• Support knowledge capture and transfer for long-duration programs
• Participate in professional society activities representing the contractor and MSFC community

Required Qualifications

Education:

• Bachelor's degree in Aerospace Engineering, Mechanical Engineering, Materials Science, or related field from an ABET-accredited program
• Master's degree or PhD strongly preferred

Experience:

• 15-20+ years of progressive experience in composite materials and structures, with significant aerospace/space systems experience
• Proven track record of successfully leading complex composite programs for launch vehicle or propulsion applications
• Extensive experience across the full mission lifecycle (concept, design, analysis, test, qualification, certification, flight operations)
• Deep hands-on experience with space-qualified composite manufacturing processes and materials
• Experience leading technical teams, mentoring engineers, and managing subcontractor technical performance
• Demonstrated experience supporting NASA programs, MSFC projects, or similar government spaceflight programs
• Familiarity with MSFC systems engineering processes, mission assurance requirements, and technical authority structure
• Experience supporting large-scale launch vehicle development programs strongly preferred

Technical Expertise:

• Expert-level knowledge of composite materials for space applications including:
  • Space-qualified carbon fiber (IM7, T800, T1000, M55J, pitch fiber), aramid (Kevlar), and glass reinforcement systems
  • Epoxy (977-3, 5320, etc.), BMI, PETI, cyanate ester, and other space-grade resin systems
  • Sandwich structures with aluminum honeycomb, Nomex, and foam cores
  • Ceramic matrix composites (CMCs) for high-temperature applications
  • Material behavior in space and launch environments (outgassing per ASTM E595, thermal cycling, vibration, acoustic, humidity)
  • Cryogenic composite applications (LOX/LH2 compatibility, coefficient of thermal expansion management)
• Mastery of composite design principles:
  • Complex laminate design and optimization for launch vehicle and propulsion loads
  • Joint design including mechanical fasteners, bonded joints, co-curing, and co-bonding
  • Damage tolerance, fracture control, and flaw growth analysis per MSFC-STD-3012 and NASA-STD-5019
  • Design for extreme thermal environments and thermal-structural coupling
  • Large-scale composite structures (diameters >5m for interstages, fairings, tank structures)
  • Pressure vessel design (composite overwrapped pressure vessels - COPVs)
  • Lightning strike protection per ARP 5412 and ARP 5414
  • Impact damage (MMOD, hail, handling damage) and environmental protection
• Advanced analysis capabilities:
  • Non-linear FEA and progressive failure analysis (Hashin, Puck, LaRC failure criteria)
  • Fatigue, fracture mechanics, and long-duration mission life prediction per CMH-17
  • Coupled thermal-structural-dynamic analysis for launch vehicle environments
  • Probabilistic analysis and uncertainty quantification
  • Multi-scale modeling from constituent to structural level (micromechanics to macromechanics)
  • Test-analysis correlation and model validation/updating
  • Buckling and post-buckling analysis of thin-walled composite structures
• Comprehensive manufacturing knowledge:
  • Hand layup, autoclave, and out-of-autoclave (OOA) processes
  • Automated fiber placement (AFP) and automated tape laying (ATL)
  • Resin transfer molding (RTM), VARTM, and vacuum infusion processes
  • Prepreg systems (unidirectional tape, fabric, tow-preg)
  • Filament winding for pressure vessels and cylindrical structures (launch vehicle cases, COPVs)
  • Thermoplastic composites and in-situ consolidation
  • Tooling design for large-scale composite structures
  • Quality control, NDI/NDE methods per ASTM standards:
    • Ultrasonic inspection (pulse-echo, through-transmission, phased array)
    • Thermography (flash, lock-in)
    • X-ray computed tomography (CT)
    • Acoustic emission, shearography
  • Environmental testing (thermal cycling, vibration per GEVS, acoustic per NASA-HDBK-7004, MMOD/hypervelocity impact)
  • Process development and qualification per ASTM D4762, ASTM D5687
• Software proficiency:
  • Advanced CAD (CATIA V5/V6, NX/Unigraphics, SolidWorks, or equivalent)
  • FEA tools (ANSYS, Abaqus, MSC Nastran, LS-DYNA, COMSOL)
  • Composite-specific software:
    • HyperSizer (sizing and optimization)
    • Fibersim (composite design and manufacturing)
    • ESAComp (laminate analysis)
    • GENOA (progressive failure analysis)
    • Helius PFA (material modeling)
    • MAC/GMC (micromechanics)
  • Programming/scripting (Python, MATLAB, Fortran) for custom analysis tools and automation
  • Requirements management tools (DOORS, Jama, Cradle)
  • Configuration management and PLM systems (Windchill, Teamcenter)
• Industry standards expertise:
  • CMH-17 (Composite Materials Handbook) - comprehensive knowledge of all volumes
  • ASTM standards for composites:
    • D3039 (tensile), D3410 (compression), D3518 (shear), D5528 (Mode I fracture)
    • D6264/D7136 (impact), D7137 (CAI - compression after impact)
    • D2344 (short beam shear), D5379 (V-notched shear)
    • E595 (outgassing), D5687 (process qualification)
  • SACMA Recommended Methods (SRM)
  • ARP standards:
    • ARP 5412 (aircraft lightning test methods)
    • ARP 5414 (aircraft lightning zoning)
    • ARP 4761 (safety assessment)
  • MIL-HDBK-17 (legacy composite design handbook)
  • AGATE (Advanced General Aviation Transport Experiments) ...