Stress Engineer/ Anaylst

The Stress Analyst is responsible for the structural analysis, substantiation, and documentation of aircraft structures and mechanical systems associated with aircraft modifications, repairs, and certification programs.

This role performs analytical evaluations to verify that aircraft structures and installations satisfy applicable strength, stiffness, fatigue, damage tolerance, and airworthiness requirements. The Stress Analyst develops engineering reports, substantiation packages, and supporting documentation required to demonstrate compliance with applicable regulatory and customer requirements.

Stress Analysts work closely with Mechanical Engineers, Mechanical Designers, Electrical Engineers, Certification Engineers, Production personnel, and external stakeholders to ensure aircraft modifications are structurally sound, manufacturable, maintainable, and certifiable. They provide technical guidance throughout the design process by validating engineering assumptions, identifying structural risks, and supporting fabrication, installation, testing, and certification activities.

Who We Are Looking For

• Bachelor's degree in Mechanical Engineering, Aerospace Engineering, or a related engineering discipline from an accredited college or university.
• Experience performing structural analyses and developing engineering substantiation for aircraft structures, mechanical systems, or aerospace products.
• Working knowledge of structural mechanics, materials, fatigue, damage tolerance, vibration, analytical methods, finite element analysis (FEA), classical hand calculations, and engineering evaluation techniques.
• Experience preparing engineering analyses, stress reports, margin of safety calculations, and supporting compliance documentation.
• Strong analytical, organizational, written, and verbal communication skills, including proficiency with Microsoft Office applications.
• Ability to work in both office and aircraft hangar environments.
• U.S. Citizenship or Permanent Resident status.

What You Will Be Doing

• Perform structural analyses and develop substantiation demonstrating compliance with applicable regulatory, customer, and airworthiness requirements for aircraft modifications, repairs, and certification programs.
• Develop engineering analyses including static strength, fatigue, damage tolerance, vibration, thermal, and other evaluations necessary to support design decisions and certification activities.
• Prepare engineering reports, stress reports, margin of safety calculations, compliance documentation, and supporting technical data required for regulatory approval.
• Review engineering designs, drawings, and proposed aircraft modifications to verify structural integrity, manufacturability, maintainability, and compliance with applicable requirements.
• Develop structural load paths, free-body diagrams, analytical models, and engineering assumptions supporting substantiation activities.
• Coordinate with Mechanical Engineers, Mechanical Design Engineers, Electrical Engineers, Certification Engineers, Production, Quality, and external stakeholders to resolve structural issues and support successful program execution.
• Support development of certification artifacts, compliance substantiation, engineering reports, test plans, and supporting documentation required for regulatory and customer approval.
• Provide technical support during fabrication, assembly, installation, troubleshooting, testing, and aircraft modification activities.
• Participate in engineering design reviews and provide technical recommendations regarding structural integrity, safety, performance, reliability, maintainability, and regulatory compliance.
• Maintain engineering analyses and supporting documentation under configuration control and ensure work products comply with company standards and procedures.
• Support continuous improvement initiatives, development of engineering analysis methods, design standards, and lessons-learned activities.
• Perform other duties as assigned by the Engineering Manager.

You Must Have

• Bachelor's degree in Mechanical Engineering, Aerospace Engineering, or a related engineering discipline from an accredited college or university.
• Experience performing structural analyses and developing engineering substantiation for aircraft structures, mechanical systems, or aerospace products.
• Working knowledge of structural mechanics, materials, fatigue, damage tolerance, vibration, analytical methods, finite element analysis (FEA), classical hand calculations, and engineering evaluation techniques.
• Experience preparing engineering analyses, stress reports, margin of safety calculations, and supporting compliance documentation.
• "Strong analytical, organizational, written, and verbal communication skills, including proficiency with Microsoft Office applications.
• Ability to work in both office and aircraft hangar environments.
• U.S. Citizenship or Permanent Resident status

Nice to Haves

• Five or more years of experience supporting aircraft modification, repair, integration, or aerospace product development programs.
• Experience developing structural substantiation supporting FAA certification, STC programs, military airworthiness, or other regulated aerospace projects.
• Familiarity with MIL-HDBK-516C airworthiness requirements and military aircraft modification programs.
• Experience performing static strength, fatigue, damage tolerance, vibration, thermal, or finite element analyses supporting aircraft structures.
• Experience developing engineering reports, substantiation packages, compliance documentation, test plans, and certification support documentation.
• Experience supporting aircraft production, modification, installation, ground testing, or flight test activities.
• Familiarity with aerospace materials, manufacturing processes, fastener systems, composite structures, and aircraft structural repair practices.
• Experience using commercial engineering analysis software such as ANSYS, FEMAP, NASTRAN, Abaqus, Mathcad, or equivalent analytical tools.
• Experience working directly with customers, DERs, FAA representatives, OEMs, suppliers, or certification authorities.
• Familiarity with configuration management, engineering release processes, and aerospace quality systems such as AS9100.