Mechanical Engineer

Join the Mission to Return Humans to the Moon!

Onyx Aerospace is seeking a highly skilled Mechanical Engineer with expertise in loads and dynamics to support the Core Stage 3 (CS3) program for NASA’s Space Launch System (SLS). This role involves advanced engineering analysis, model verification, and load spectrum development critical to ensuring the structural integrity and reliability of launch vehicle hardware. The successful candidate will work closely with Boeing and NASA engineering teams, leveraging industry-leading tools and processes to support dynamic model verification, fatigue spectra development, and secondary structure loads analysis.

What You’ll Do

CS3 Dynamic Model Verification:

• Build CS3 models representing CS1 modal test set-up, including verification of mass distribution against CS Mass Properties Reports.
• Develop two models for each configuration: free-free and suspended.
• Perform modal analyses to determine equivalent target modes from analysis.
• Compute first mode shapes and frequencies, followed by calculation of verification metrics (Modal Assurance Criteria and Cross Orthogonality matrices) for each model.
• Support documentation of the dynamic model verification effort.

CS3 Structural Fatigue Spectra Development:

• Generate spectra-specific OTM to be used for Coupled Loads Analysis (CLA).
• Process CLA time history output data to generate max, min, mean, and RMS data for every load case.
• Support load case down selection for spectra development.
• Combine low and high frequency spectra to create combined structural fatigue spectra for CS3 critical parts and components.
• Support documentation of fatigue spectra development.

CS3 Secondary Structure Loads Development:

• Generate or modify breakout FEM to be used for base drive.
• Perform random response analysis using the generated FEM.
• Combine CLA data with random response data to generate combined secondary structure loads.
• Support documentation of secondary structure loads development.

What You Bring

Minimum Qualifications:

• Bachelor’s degree in Mechanical, Aerospace, or Structural Engineering, or related technical discipline.
• 5+ years of experience in loads, dynamics, or structural analysis within aerospace or related industry.
• Proficiency in Finite Element Modeling (FEM) and modal analysis techniques.
• Experience with load spectrum development, fatigue analysis, and dynamic verification methods.
• Strong analytical, documentation, and communication skills.
• Ability to work on-site in Huntsville, AL, Titusville, FL, Houston, TX or New Orleans, LA, or relocate upon offer acceptance.

Preferred Qualifications:

• Experience supporting NASA or large aerospace OEM programs (e.g., Boeing, Lockheed Martin).
• Familiarity with Boeing loads and dynamics tools and processes.
• Knowledge of structural dynamics verification metrics such as Modal Assurance Criteria (MAC) and Cross Orthogonality.
• Proficiency in CLA and random vibration analysis.

What We Offer

The opportunity to work on a high-profile NASA human spaceflight program. Collaboration with leading engineers in loads, dynamics, and aerospace structures. Competitive compensation and relocation assistance. Career growth potential in the expanding space industry. A role in shaping the future of space exploration.