Senior Aircraft Stress Analysis Engineer

Senior Stress Analysis Engineer

An employer in Greenville, TX is seeking two experienced Senior Stress Analysis Engineers to support complex aircraft modification, certification, sustainment, and repair programs. This role is ideal for engineers who bring strong structural fundamentals, adaptable analysis skills, and a leadership mindset, and who are comfortable working outside of rigid OEM-specific tool chains. Engineers who enjoy mentoring and leading technical teams, rather than solely performing individual contributor analysis work, will be a great fit for this opportunity.

We are specifically interested in engineers who can independently develop and apply structural analysis methods, tools, and substantiation approaches rather than relying solely on proprietary OEM processes.

Responsibilities include:

• Perform classical hand calculations and develop finite element models (MSC Nastran/FEMAP) to predict internal loads, displacements, stresses, and margins of safety for aircraft structures.
• Analyze aircraft primary structure including fuselage frames, longerons, skins, floor beams, fittings, pressure structure, and major structural reinforcements.
• Support major aircraft modifications, repairs, and sustainment activities on FAA-certified (14 CFR Part 25) fixed-wing transport and business jet aircraft.
• Generate free-body diagrams, internal load paths, margins of safety, and structural substantiation using accepted aerospace engineering methodologies. Perform static strength analysis and support fatigue and damage tolerance evaluations as required.
• Develop structural test plans, post-process test data, and establish allowable strength data to support certification and airworthiness findings.
• Generate and peer review detailed stress reports supporting aircraft certification, repairs, modifications, and airworthiness compliance. Collaborate closely with design engineers to develop aircraft modifications and installations that satisfy FAA and military airworthiness requirements.
• Review engineering design data using CAD and PLM tools to ensure structural requirements are properly incorporated into the design.
• Support Material Review Board (MRB), repair substantiation, field modifications, and engineering investigations as needed.
• Manage assigned tasks within scope, budget, and schedule requirements.
• Estimate engineering labor hours for proposals and manage labor forecasts for a small team of stress engineers.
• Develop analysis automation tools, spreadsheets, scripts, or engineering utilities to improve efficiency and standardize analysis methods.