Stress Support Engineer

Stress Support Engineer

The Stress Support Engineer will provide structural analysis, ensuring the integrity, safety, and airworthiness of composite and metallic nacelle components. The role involves supporting design activities, performing detailed stress calculations, validating modifications, and providing rapid-response technical support to production and in-service teams.

Structural Analysis & Certification

• Perform static, fatigue, and damage-tolerance analyses of nacelle components (inlet, fan cowl, thrust reverser, EBU, exhaust system).
• Develop hand calculations, FEM analyses, and detailed substantiation reports in accordance with EASA/FAA requirements.
• Validate design changes, concessions, and repair solutions through structural justification and compliance documentation.
• Support the creation and approval of certification evidence for major and minor modifications.

Design Support

• Work closely with design engineers to provide stress input during concept development, detail design, and manufacturing phases.
• Participate in multidisciplinary design reviews (DMR, PDR, CDR), providing structural recommendations and risk assessments.
• Ensure structural integrity requirements are embedded in new or modified nacelle designs.

Production & In-Service Support

• Provide rapid stress assessments for concessions, NCRs, and shop-floor queries from manufacturing sites.
• Evaluate in-service issues, fleet-wide technical problems, and support development of permanent and temporary repairs (SRM, TechDocs).
• Collaborate with Customer Support, MRO partners, and airworthiness authorities when required.

Tools & Methods

• Build and validate finite element models (FEM) for nacelle assemblies using tools such as Patran/Nastran, HyperMesh, Abaqus, or similar.
• Use tools and methods (ISAMI, PRIMES, LUCIE, etc.) where applicable.
• Support continuous improvement of stress methodologies and analysis standards.

Required Qualifications

• Bachelor's or Master's degree in Aerospace Engineering, Mechanical Engineering, or related field.
• Proven experience in structural analysis of aircraft primary/secondary structures, preferably nacelles or composite structures.
• Strong knowledge of static, fatigue, and damage-tolerance analysis methods.
• Proficiency with FEM tools (Nastran, Abaqus, etc.) and classical hand-calculation methods.
• Understanding of aerospace certification requirements (EASA CS-25, FAA Part 25).
• Ability to interpret engineering drawings, material specifications, and manufacturing processes.

Preferred Experience

• Knowledge of composite repair design and substantiation.
• Familiarity with stress methodologies (ISAMI, ISAMI-DT, ACD investigations).
• Experience supporting production lines and/or in-service engineering teams.

Soft Skills

• Strong analytical problem-solving capability.
• Ability to work in a fast-paced, multi-disciplinary environment.
• Good communication skills for coordination with design offices, production, and customer support.
• Proactive, detail-oriented, and capable of managing multiple priorities.