Stress Engineer II

Position Summary

We are seeking a Mechanical Stress Engineer with a solid background in aircraft structures, military standards, and engineering metals. The ideal candidate will hold a bachelor’s degree in mechanical engineering and possess a minimum of 10 years of relevant experience in the aerospace industry. This role focuses on evaluating metallic and composite structures through classical stress analysis methods, finite element analysis, and structural testing.

The engineer will collaborate with senior engineers, production teams, quality personnel, and cross‑functional teams to contribute to high‑quality product development.

Examines and analyzes how much stress a structure or component can handle through static, fatigue, and vibration tests.

• Performs classical hand calculations and finite element analysis (FEA) on composite structures, reviews engineering drawings, and develops load cases.
• Collaborates with mechanical and integration engineers to optimize, certify, and produce designs.
• Prepares detailed analysis reports on safety, strength, and producibility of designs.
• Analyzes and checks structural engineering data produced by other engineering groups to ensure it meets the structural requirements.
• Creates and develops structural engineering substantiation reports that will be used to certify repair and modification data.
• Generates stress analysis notes in a usable, traceable file that serves as a historical substantiation record of the repair or modification.
• Creates, develops, and implements test procedures as required to obtain certifiable allowable data.
• Develops finite element models to aid in the development of design and certification data.
• Provides input and suggestions for continuous improvement of various department procedures, controls, flows, and/or systems.

• Proficient with Solid Works and Solid Works PDM.
• Skilled in structural members, 3D mechanical routing, and managing large assemblies.
• Strong understanding of Geometric Dimensioning and Tolerancing (GD&T).
• Familiar with FAA standards and military specifications.
• Ability to take initiative in identifying and solving stress challenges.
• Effective communication skills, both verbal and written.
• Collaborative mindset and ability to work in a multidisciplinary team.
• Willingness to liaise with planning, production, and quality departments as needed.
• Committed to upholding company values and engineering standards.

• Bachelor’s degree in mechanical, aerospace, or civil engineering.
• Minimum of 5 years of mechanical engineering experience, preferably in the aerospace industry.
• Familiarity with various metals and their use in structural applications.
• Working knowledge of military parts, fasteners, and standards.
• Experience with CAD and design tools, including Solid Works (CATIA or AutoCAD a plus).
• Ability to manage multiple tasks and support projects under tight deadlines.
• Solid analytical and problem‑solving skills.

• International and domestic travel in support of product designs, implementations, or ongoing service.
• Able to sit or stand for long periods of time.

• This is a Exempt, Full‑Time Position. Warehouse and office environment.
• KA is located at 3606 SW 36th Street, Suite 101, San Antonio, TX 78226.
• Employer paid medical, dental and vision.
• KA is an equal opportunity employer.