FEA Engineer

Senior Finite Element Analysis (FEA) Engineer – Aerospace

LHH is partnering with a leading aerospace organization to identify a Senior Finite Element Analysis (FEA) Engineer to support the design, analysis, and optimization of critical aerospace structures and components. This role will play a key part in ensuring the safety, reliability, and performance of systems used in spacecraft, rockets, and satellite platforms.

Responsibilities

• Perform advanced finite element analysis (FEA) to evaluate structural performance, including stress, strain, thermal, vibration, fatigue, and dynamic loading conditions
• Support design optimization efforts, providing simulation-driven insights to improve structural efficiency, weight reduction, and performance while maintaining safety margins
• Develop and refine 3D simulation models of aerospace components and systems using industry-standard FEA tools (ANSYS preferred; Abaqus, NASTRAN, LS-DYNA accepted)
• Analyze material behavior and structural integrity under extreme conditions such as high temperatures, pressure, acceleration, and dynamic events
• Collaborate with test teams to correlate simulation results with physical test data, refining models and improving prediction accuracy
• Document and present detailed technical reports, including clear recommendations based on analytical findings
• Partner cross-functionally with propulsion, systems, manufacturing, and integration teams to incorporate FEA results throughout the product development lifecycle
• Ensure all analyses comply with aerospace industry standards, safety regulations, and certification requirements
• Participate in design reviews and contribute to risk assessment and mitigation strategies

Required Qualifications

• Bachelor's degree in Aerospace Engineering, Mechanical Engineering, or a related field (Master's degree preferred)
• 5+ years of experience performing FEA or structural analysis within aerospace or defense environments
• Strong background in structural mechanics, materials science, and mechanical behavior
• Proficiency with FEA software (ANSYS preferred; Abaqus, NASTRAN, LS-DYNA accepted)
• Experience with nonlinear analysis (material, geometric, and contact)
• Experience with explicit dynamics simulations (e.g., crash events, drop tests, fabric/airbag models)
• Demonstrated expertise in composite structure analysis, including laminates, sandwich panels, ply-level allowables, and failure criteria
• Strong foundation in classical stress analysis and free-body diagram development
• Working knowledge of aerospace materials and manufacturing processes
• Experience with CAD tools such as Solid Works, CATIA, or Siemens NX
• Strong documentation and reporting skills using standard productivity tools

Nice to Have

• Experience analyzing aerospace structures such as airframes, rocket bodies, propulsion systems, or satellite assemblies
• Exposure to thermal, vibration, or fatigue analysis for aerospace applications
• Knowledge of design for manufacturability (DFM) and manufacturing constraints
• Familiarity with advanced aerospace materials, including composites, metals, and high-performance alloys
• Experience supporting space exploration programs or working with space-related organizations
• FEA or advanced simulation certifications
• Knowledge of composites manufacturing processes
• Scripting skills using Python, MATLAB, or VBA

Soft Skills

• Strong collaboration skills with the ability to work across multidisciplinary engineering teams
• Excellent analytical and problem-solving capabilities
• High attention to detail in a technically complex environment
• Ability to manage multiple priorities and meet deadlines
• Self-motivated with a passion for aerospace engineering and innovation

Why Work with LHH

LHH specializes in connecting highly skilled engineering professionals with innovative organizations working at the forefront of advanced technology. This opportunity offers the chance to contribute to technically challenging programs with meaningful real-world impact, while working alongside experienced engineering teams solving complex problems.

Pay Details: $ to $ per year

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Megan McQuay Equal Opportunity Employer/Veterans/Disabled Military connected talent encouraged to apply