Design Engineer - FRP/Tank Structures

JOB DESCRIPTION

Job Summary

The Design Engineer - Custom Composite Structures is responsible for the design, analysis, and certification of reinforced thermoset plastic (RTP) vessels and piping systems in compliance with ASME RTP-1, ASME NM.2, and EN 13121. The role involves performing stress and strain analysis, developing laminate designs, and validating performance through analytical and test methods.

The engineer reviews and approves fabrication drawings to ensure compliance with design requirements, codes, and manufacturability, and supports the preparation of Fabricator's Design Reports (FDRs) and ASME quality programs. This position requires strong knowledge of composite materials, laminate mechanics, and fabrication processes such as filament winding and contact molding.

Working closely cross-functional teams, the Design Engineer plays a critical role in ensuring product reliability, regulatory compliance, and efficient execution of high-integrity composite systems.

Main Responsibilities

• Develop and certify design calculations, drawings, and specifications for composite pressure vessels and piping systems per ASME RTP-1, ASME NM.2, EN 13121, and related standards (BS 4994, API 15LR/15HR).
• Prepare and maintain the Fabricator's Design Report (FDR) in compliance with the User's Basic Requirements Specification (UBRS) and ASME Quality Control procedures.
• Perform advanced laminate stress and strain analyses, including modeling of anisotropic material behavior and evaluation of ply-by-ply responses using Classical Laminate Theory (CLT).
• Conduct finite element analysis (FEA) to verify compliance with ASME stress and strain-limit criteria and to assess vessel and piping performance under operating and test conditions.
• Define laminate architectures, reinforcement sequences, corrosion-barrier configurations, and joint details to meet structural and chemical service requirements.
• Review and approve fabrication and layout drawings, ensuring manufacturability, code compliance, and alignment with design intent.
• Verify that drawings accurately reflect laminate details, dimensions, tolerances, joint configurations, and BOM, ensuring manufacturability and adherence to company drafting standards.
• Provide technical guidance to designers/drafters to ensure manufacturability, accuracy, and adherence to company drafting standards.
• Support design qualification testing, material property development, and correlation of analytical models with experimental data.
• Collaborate with Quality Assurance, Inspection, and Manufacturing to ensure design execution and documentation meet ASME audit and customer requirements.
• Provide engineering support for composite fabrication processes such as filament winding, contact molding, secondary bonding, and post-cure.
• Participate in design reviews, code audits, and nonconformance investigations, supplying root-cause analysis and corrective-action recommendations.
• Prepare technical documentation, including design reports, deviation requests, and installation procedures for customer and regulatory submittals.
• Contribute to continuous improvement initiatives, identifying opportunities to enhance design efficiency, manufacturability, and cost-effectiveness across composite product lines.

Qualification and Experience Requirements

Essential

• Bachelor's or master's degree in mechanical, Materials, or Composite Engineering (or closely related field).
• Minimum of 5 years of design and analysis experience with composite pressure vessels, tanks, or piping systems.
• Minimum 2 years of design and analysis experience with composite pressure vessels, tanks, or piping systems.
• Fluent in English with exceptional technical writing and presentation skills.
• Willingness to travel internationally as required.

Desirable

• Code Expertise: Proven working knowledge of ASME RTP-1, ASME NM.2, EN 13121, BS 4994, AWWA M45, and API 15LR/15HR design standards.
• Practical understanding of filament winding, contact molding, secondary bonding, and post-cure processes.
• Laminate mechanics, Classical Laminate Theory (CLT), and quadratic interaction failure criteria (Tsai-Wu, Hill).
• Finite element modelling of anisotropic materials using ANSYS, Abaqus, or equivalent tools.
• CAD proficiency in AutoCAD and SolidWorks for 3D modelling and drafting.
• Familiarity with ERP systems (e.g., Oracle) and technical document control procedures.

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