Structural Dynamics & Aeroelasticity Engineer

About Mach Industries

Founded in 2023, 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 350 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.

The Role

Responsible Engineer for aeroelastic analysis and for the design, execution, and analysis of static and dynamic tests that verify structural strength, load paths, stiffness, and dynamic characteristics of unmanned aircraft platforms. The engineer owns structural-dynamic and aeroelastic models, plans and runs the tests that validate those models, and closes the loop between prediction and measurement.

The role supports the full product development cycle by ensuring that structural performance, strength, stiffness, fatigue life, flutter margins, and dynamic characteristics are predicted, measured, correlated, and validated against certification and design requirements. The engineer works with design, stress, flight sciences, flight controls, manufacturing, and instrumentation to produce airworthy structure and a flight-cleared envelope.

Key Responsibilities

• Own structural-dynamic and aeroelastic finite element models from concept through flight clearance, including mass, stiffness, and damping of the airframe, control surfaces, stores, and landing gear.
• Establish aeroelastic design criteria, flutter and divergence margins, and loads assumptions for new and modified configurations.
• Perform normal-modes, static aeroelastic, flutter, and aeroelastic loads analyses, and deliver design loads and clearance recommendations to stress, design, and flight sciences.
• Assess control-surface mass balance, freeplay, stiffness, and relevant failure modes, and recommend design changes that restore required flutter margins.
• Support configuration trades with aeroelastic screening and recommend stiffness or mass-balance changes that keep the design flutter-free.
• Develop static, modal, and aeroelastic test plans, procedures, load schedules, instrumentation layouts, and risk assessments.
• Design structural test fixtures, reaction frames, load-introduction systems, and actuator/whiffletree arrangements that simulate aerodynamic, landing, propulsion, and operational loads.
• Specify, install, and operate structural instrumentation, including strain gages, displacement transducers, load cells, inclinometers, accelerometers, and thermocouples.
• Conduct proof, limit, ultimate, and component qualification tests, and plan and execute Ground Vibration Tests and related modal surveys.
• Support aeroelastic and flutter-model wind-tunnel tests and flight-flutter testing, including test-point definition, excitation methods, go/no-go criteria, and data reduction.
• Monitor structural response during testing, assess safety and test progress in real time, and reduce measured data to verify compliance with design requirements.
• Correlate measured loads, strains, deflections, frequencies, and mode shapes with analytical predictions and update models accordingly.
• Prepare analysis, test, flutter, and certification documentation suitable for airworthiness and customer review.

Required Qualifications

• Bachelor’s degree in Aerospace Engineering, Mechanical Engineering, or a closely related engineering discipline.
• Minimum 3 - 8 years of experience in aircraft structural dynamics, aeroelasticity, flutter, modal testing, or related aerospace analysis and test.
• Demonstrated ability to perform and interpret structural-dynamic and aeroelastic analyses, including normal modes, flutter, and aeroelastic loads.
• Experience planning, executing, and documenting structural or modal test programs.
• Experience correlating test results with finite-element models and using that correlation to refine analysis predictions.
• Proficiency with finite-element analysis tools (MSC Nastran or equivalent) and with engineering scripting in MATLAB or Python.
• Working knowledge of aerospace test instrumentation and data-acquisition systems.
• Understanding of digital signal processing as applied to structural dynamics and modal testing.
• Ability to develop test and analysis plans and write clear technical reports.
• Strong analytical, troubleshooting, and communication skills, with the ability to work across design, stress, flight sciences, flight test, and manufacturing.
• Ability to travel and support ground and flight-test activities in laboratory, wind-tunnel, and flight-line environments.

Preferred Qualifications

• Master’s degree in Aerospace or Mechanical Engineering with emphasis in structural dynamics, aeroelasticity, or flight sciences.
• Experience creating and maintaining Global Finite Element Models (GFEM), including assembly of component models, load-path verification, and model checkout.
• Direct experience clearing a flight envelope: flutter analysis, GVT correlation, flight-flutter-test support, and written flutter substantiation.
• Hands-on experience with Ground Vibration Testing, Experimental Modal Analysis (EMA), Operational Modal Analysis (OMA), and modal-parameter identification.
• Experience conducting static and dynamic wind-tunnel testing, including aeroelastic and flutter-model testing, calibration, and data reduction.
• Experience with aeroservoelasticity, control-surface freeplay, actuator modeling, and closed-loop flutter.
• Familiarity with applicable airworthiness and loads/flutter criteria (for example MIL-A-8870, JSSG-2006, MIL-STD-1530, 14 CFR 23/25.629, or equivalent customer specs).
• Experience with high-aspect-ratio or otherwise flexible unmanned airframes, store configurations, and rapid prototype or incremental-clearance programs.
• Proficiency with FEMAP, HyperMesh, ANSYS, ZAERO, Nastran SOL 144/145/146, LabVIEW, NI DIAdem, Siemens Simcenter Testlab, Dewesoft, Crystal Instruments EDM, or equivalent tools.

Additional Requirements

• Available to work extended hours and weekends as needed

ITAR Requirements

To conform to U.S. Government export regulations, applicant must be a (i) U.S. citizen or national, (ii) U.S. lawful, permanent resident (aka green card holder), (iii) Refugee under 8 U.S.C. § 1157, or (iv) Asylee under 8 U.S.C. § 1158, or be eligible to obtain the required authorizations from the U.S. Department of State. Learn more about the ITAR here.

Engineer$115,000-$150,000 USDSenior Engineer$155,000-$195,000 USD

At Mach, we believe that compensation is more than just a paycheck. It's a comprehensive package designed to reward the time, skills, and expertise you bring to our team. We are committed to offering competitive compensation that is equitable, transparent, and aligned with market trends.

Key Elements of Our Compensation Philosophy:

• Competitive Salaries: We continuously research market rates to ensure our salaries are competitive with those in our industry and geographic location.
• Performance-Based Incentives: Our bonus structure is tied to both individual and company performance, creating a win-win scenario that motivates our team members to excel.
• Equity Participation: We offer stock options or equity to employees, ensuring that you share in the success and growth of the company.
• Benefit Packages: Our benefits include healthcare, dental and vision plans, retirement savings, and paid time off, because we understand that your well-being extends beyond the office.
• Professional Development: We allocate funds for continuing education, training, and career growth.
• Transparency: We are committed to openness about our compensation tiers and how decisions are made, ensuring trust and mutual respect.

By joining Mach, you’re not just accepting a job - you’re becoming a key part of a team that values your contributions and invests in your growth. Together, we aim to create a rewarding environment that sets the stage for long-term success.

Data Privacy
To view Mach Industries candidate data privacy policy, please visit https://machindustries.com/privacy-policy.

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!