Senior Design Engineer
2 weeks ago
Senior Design Engineer
Location: Houston, TX
Overview: We are seeking a highly skilled Senior Design Engineer with a unique blend of experience in downhole oil & gas equipment design and composites technology. The ideal candidate will possess a strong background in mechanical engineering, coupled with expertise in the design, analysis, and manufacturing of composite materials for downhole applications.
Responsibilities:
- Composite Design Expertise: Lead the design and development of downhole drilling and completion tools with a focus on incorporating composite materials for enhanced performance, durability, and corrosion resistance.
- Material Selection: Evaluate and select appropriate composite materials, resins, and reinforcements based on application requirements, environmental conditions, and performance specifications.
- Structural Analysis: Conduct structural analysis and simulation studies to assess the mechanical integrity, load-bearing capacity, and fatigue life of composite components, ensuring compliance with industry standards and safety regulations.
- Hybrid Design Integration: Collaborate with cross-functional teams to integrate composite components with traditional metal structures, optimizing design configurations for weight reduction, cost efficiency, and reliability.
- Manufacturing Process Optimization: Work closely with manufacturing engineers to optimize composite manufacturing processes, including layup techniques, curing cycles, and quality control procedures, to achieve consistent and repeatable results.
- Prototype Development: Lead the fabrication and testing of composite prototypes, analyze test data, and iterate designs to optimize performance and address any design challenges or deficiencies.
- Documentation and Reporting: Prepare comprehensive design documentation, including material specifications, CAD models, technical reports, and test plans, to document design decisions and facilitate communication with stakeholders.
- Risk Management: Identify and mitigate potential risks associated with composite design and manufacturing processes, proactively addressing issues related to material compatibility, structural integrity, and regulatory compliance.
Requirements:
- Bachelor's degree in Mechanical Engineering, Materials Science, or related field; Master's degree preferred.
- Minimum of 5 years of experience in downhole oil & gas equipment design, with a focus on composite materials and structural engineering.
- Proficiency in CAD software (e.g., SolidWorks, CATIA) and finite element analysis (FEA) tools (e.g., ANSYS, Abaqus) for composite structural analysis.
- Strong understanding of composite materials and manufacturing processes, including filament winding, resin infusion, and autoclave curing.
- Experience with composite characterization techniques, such as mechanical testing, thermal analysis, and non-destructive testing (NDT).
- Demonstrated ability to manage complex engineering projects, from concept development through prototyping and commercialization, with a track record of successful product launches.
- Excellent communication skills, with the ability to collaborate effectively with multidisciplinary teams and present technical concepts to internal and external stakeholders.
Preferred Qualifications:
- Experience with downhole tool qualification testing according to industry standards (e.g., API, ISO).
- Knowledge of corrosion protection techniques and coatings for composite materials in aggressive downhole environments.
- Familiarity with composite failure analysis methods, including fracture mechanics and fatigue analysis.
- Prior experience in technology transfer and scaling up composite manufacturing processes from laboratory-scale to production-scale.
- Strong project management skills, including budgeting, resource allocation, and milestone tracking.
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