Structural Analysis Engineer; Prometheus

Structural Analyst / Senior Structural Analyst

Prometheus Energetics is seeking an experienced Structural Analyst / Senior Structural Analyst to serve as a primary technical authority for the structural integrity, finite element analysis (FEA), and fracture mechanics of Solid Rocket Motor (SRM) structures. Reporting directly to the Director of Engineering, this role owns the structural lifecycle-from initial sizing and material characterization through coupled load modeling, qualification testing, and high-rate production support.

Solid Rocket Motor hardware operates under severe structural environments: extreme internal pressures, high motor case growth, intense thermal-mechanical stresses, structural vibration, high-g acceleration, and viscoelastic grain strain. The ideal candidate brings 4 to 10 years of hands-on structural engineering experience in composite/metallic pressure vessels, nozzles, or energetic propellant grain mechanics, combining advanced computational modeling skills with practical experience in structural test correlation and factory floor integration.

• Lead structural sizing, margin-of-safety assessments, and strength evaluations for solid rocket motor components, including composite filament-wound cases, metallic pressure vessels, nozzle structures, igniter housings, and interstage structures.
• Evaluate orthotropic and anisotropic material behavior for composite structures (e.g., carbon fiber/epoxy wet-wound and prepreg layups) and high-strength metallic alloys (e.g., titanium, maraging steel, aluminum).
• Characterize viscoelastic material behavior, structural margin, and cumulative damage models for solid propellant grains, liners, and insulation bond lines across storage, transportation, thermal cycling, and operational firing profiles.
• Define structural interface requirements, fastener joint designs, skirts, polar cleats, and bond line shear limits to ensure structural integrity across proof testing, flight, and post-burn heat-soak environments.
• Support scalable manufacturing processes (e.g., fiber placement, automated tape laying, hand layup, hydrotesting, and machining) to transition structural designs from prototype into high-rate production.

• Develop and maintain complex 2D and 3D finite element models (FEM) using industry-standard tools (e.g., Abaqus, ANSYS, Nastran/Patran, Hyper Mesh, or custom solvers).
• Perform linear and non-linear static, dynamic, modal, random vibration, transient response, and buckling analyses for primary and secondary motor structures.
• Conduct coupled thermal-structural and pressure-stress analyses, incorporating temperature-dependent material properties, internal ballistics pressure-time curves, and aerodynamic flight loads.
• Execute fracture mechanics, damage tolerance, fatigue life, and composite ply-by-ply progressive failure analyses (e.g., Tsai-Wu, Hashin criteria) to establish structural margins of safety.
• Conduct trade studies and optimization to minimize structural mass while maintaining required structural safety factors (e.g., MIL-STD-1522A, NASA-STD-5001).

• Plan, execute, and analyze structural test campaigns, including hydroburst testing, proof pressure testing, modal survey testing, structural load cell calibration, and environmental vibration/shock tests.
• Collaborate with test engineers to define instrumentation requirements, specifying strain gauge placement, rosette configurations, displacement sensors (LVDTs, DIC), and load cell locations.
• Correlate analytical predictions against measured test data (strain profiles, growth rates, burst pressures, resonance frequencies) to validate and refine finite element models.
• Lead structural root-cause investigations and failure review boards (FRACAS/MRB) for structural anomalies, such as composite delamination, bond line debonding, yield nonconformances, or premature pressure vessel failure.

• Work directly with internal ballisticians, thermal analyst counterparts, materials scientists, and manufacturing engineers to deliver fully integrated motor designs on schedule.
• Author clear structural analysis reports (SAR), stress documentation, material design allowables decks, and qualification verification artifacts.
• Present technical findings, margin summaries, and structural design rationale at major program milestones (PDR, CDR, TRR, MRB).
• Serve as a technical mentor to junior engineering staff in finite element techniques, composite failure criteria, and structural verification methodologies.
• Ensure strict compliance with ITAR, EAR, site energetics safety standards, and environmental safety guidelines across all design and lab operations.

• Bachelor's degree in Aerospace Engineering, Mechanical Engineering, Structural Engineering, or a closely related technical field from an accredited institution.
• Experience:
• Structural Analyst:
  Minimum…