Structural Analysis Engineer – Advanced FEA & Stress Design

In this role you apply cutting-edge Finite Element Analysis (FEA) to safeguard the integrity of airframes, vehicles and high-performance hardware. The position blends stress engineering craft with data-driven optimisation. You will interrogate models, challenge assumptions and deliver designs that are lighter, stronger, safer.

Key Responsibilities

- Execute linear, nonlinear and transient FEA to evaluate stress, strain, vibration, shock and fatigue.  

- Build and refine high-fidelity meshes in ANSYS, Abaqus, Nastran and LS-DYNA.  

- Simulate extreme events—impact, blast, bird-strike, drop-test—and translate results into actionable design changes.  

- Correlate analytical predictions with static, modal and fatigue test data; close gaps between theory and reality.  

- Develop Python scripts that automate meshing, post-processing and report generation, cutting cycle time by up to 40 %.  

- Optimise metallic and composite structures for mass, stiffness and manufacturability through parametric studies and design-of-experiments.  

- Document assumptions, boundary conditions and safety factors in crisp, audit-ready reports for certification authorities.  

- Mentor junior analysts, codify best practices and champion simulation-driven decision making across multi-disciplinary teams.

Required Qualifications

- Bachelor’s or Master’s degree in Aerospace, Mechanical, Civil or Structural Engineering.  

- Minimum 5 years’ professional experience performing advanced FEA of complex assemblies.  

- Proficiency with at least two major solvers (ANSYS Mechanical, Abaqus Standard/Explicit, MSC Nastran, LS-DYNA).  

- Demonstrated competence in fatigue, fracture mechanics and vibration theory.  

- Hands-on Python or MATLAB scripting for model manipulation and data analytics.  

- Solid understanding of material science for aluminum alloys, steels, titanium and composites.  

- Eligibility to work in the United States without sponsorship now or in the future.

Desirable Skills

- HyperMesh or similar high-end pre-processor for large shell/solid models.  

- Topology and shape optimisation, including generative design workflows.  

- Knowledge of DO-160, MIL-HDBK-5/17 or NASA-STD materials databases.  

- Experience integrating digital twin data into FEA correlation loops.  

- Familiarity with cloud-based HPC clusters and containerised simulation pipelines.