Senior Engineer - Composite Materials

ABOUT THE ROLE
HALCON is seeking an experienced Senior Engineer – Composite Materials to join our Rocket Propulsion team. In this role, you will lead the design, development, analysis, and qualification of advanced composite structures that are critical to the performance and reliability of next-generation solid rocket motor systems.
This is an opportunity to work on cutting-edge aerospace and defense technologies, contributing to the development of composite motor cases, nozzle structures, thermal protection systems, and propulsion hardware from concept through qualification and production.

RESPONSIBILITIES

• Lead the design and structural analysis of composite components for solid rocket motors, including motor cases, nozzle structures, thermal insulation systems, and airframe components.
• Develop and qualify composite manufacturing processes such as filament winding, hand lay-up, tape winding, and automated fiber placement (AFP).
• Perform structural assessments using Finite Element Analysis (FEA) and Classical Laminate Theory (CLT) to validate designs and establish structural margins.
• Support rocket motor development programs through material selection, insulation design, and propulsion system integration activities.
• Define and execute composite material qualification and testing plans in accordance with aerospace and defense standards.
• Collaborate with propulsion, thermal, mechanical, manufacturing, and quality teams to ensure successful product development and integration.
• Support prototype builds, proof testing, hydrostatic testing, burst testing, and qualification campaigns.
• Review supplier qualifications, process specifications, and composite manufacturing data packages.
• Mentor junior engineers and provide technical guidance on composite design, manufacturing, and inspection activities.
• Develop engineering specifications, manufacturing documentation, technical reports, and design review presentations.
• Evaluate emerging materials, manufacturing technologies, and innovative structural concepts to support future propulsion programs.

BASIC QUALIFICATIONS

Education

• Bachelor's degree in Aerospace Engineering, Mechanical Engineering, Materials Engineering, Polymer Engineering, or a related discipline

Experience

• Minimum 8 years of experience in composite structures engineering within aerospace, defense, space, or advanced manufacturing environments. Proven experience designing and developing composite structural components for high-performance applications.
• Hands-on experience with:
  • Filament winding
  • Hand lay-up
  • Automated Fiber Placement (AFP)
  • Automated Tape Layup (ATL)
  • Tape winding processes

Technical Expertise

• Strong knowledge of composite materials, structural mechanics, and manufacturing processes.
• Experience with composite structural analysis using:
  • Abaqus
  • Nastran
  • ANSYS or equivalent FEA tools
• Proficiency in Classical Laminate Theory (CLT) and composite failure analysis.
• Experience with material qualification, testing, and certification activities.
• Familiarity with ASTM standards, CMH-17/MIL-HDBK-17, and aerospace quality requirements.
• Understanding of propulsion systems, pressure vessels, rocket motor structures, or related aerospace applications is highly desirable.

PREFERRED QUALIFICATIONS
Candidates with experience in one or more of the following areas are strongly encouraged to apply:

• Solid Rocket Motors (SRM)
• Missile Systems
• Launch Vehicles
• Space Propulsion
• Composite Pressure Vessels
• Aerospace Primary Structures
• Defense Systems Development

WHY CHOOSE THE COMPANY
Launched in November 2019, the UAE's the company is one of the world's leading advanced technology groups, established to develop agile, bold and disruptive solutions for defence and beyond, and to be a catalyst for change and transformation. It is dedicated to bringing breakthrough innovations, products, and services to market with greater speed and efficiency, to position the UAE as a leading global hub for future industries, and to creating clear paths within the sector for the next generation of highly skilled talent to thrive.
At the company, the real investment goes beyond compensation. Through our dedicated learning academy and digital learning platforms, employees have access to extensive opportunities to develop new skills, deepen their expertise, and advance their careers. Combined with the freedom to innovate, strong career support, and the opportunity to collaborate with world-class talent from across the globe, the company is a place where you can continue to grow, keep learning, and turn ambitious ideas into meaningful outcomes.
Working at the company also comes with a package that genuinely reflects how much we value our people. Salaries are highly competitive and tax-free and, depending on your role and seniority, benefits can include family visas, annual flight tickets, medical insurance for you and your dependents, and education allowances for your children.

CANDIDATE PRIVACY & EQUAL OPPORTUNITY STATEMENT
If you feel your skills, experience and potential are a strong match for a role, we encourage you to apply even if you don’t meet every requirement. We are genuinely interested in what you can bring to the company.
Any information you share as part of your the company candidate profile or job application will be handled in accordance with applicable data protection and privacy regulations.
the company is an equal opportunity employer committed to building a diverse, inclusive, and high-performing workforce. We believe every individual deserves to be treated with fairness, respect and dignity, and our employment decisions reflect that. We do not discriminate based on race, colour, nationality, ethnicity, religion, gender, marital status, age, disability, pregnancy or parental status, or any other characteristic protected by applicable law.
As a global organisation, effective collaboration across international teams is central to how we work, so English proficiency is required for all roles unless otherwise stated in the job posting.
Please note that the company does not accept unsolicited resumes from recruitment agencies. Any resumes in the absence of a formally executed agreement in place will be deemed the property of the company, and no placement fees or compensation will be payable in respect of such submissions.