Sr. Stress Engineer

The Senior Stress Engineer at AEVEX Aerospace is responsible for analyzing primary & secondary aircraft structures to show compliance with FAA 14CFR Part 23 & Part 25 regulations. These analyses include loads development, classical hand calculations, Finite Element (FEM) modeling, fatigue & damage tolerance assessment and testing of aircraft modifications involving both metallic & composite structure and are thoroughly documented in formal structural substantiation reports.Essential Functions: Provides stress analysis of metallic & composite structures using classical hand calculations and finite element modeling (FEM) with advanced meshing techniquesPerforms loads develop in support of static, dynamic and fatigue & damage tolerance assessmentsDevelops Fatigue & Damage Tolerance (F&DT) reportsOther functions may include basic thermal analysis, basic aero-elastic flutter, dynamic response, non- linear analysis, pre- and post-test analysis, structural optimization, and software programmingCompletes stress notes & develops macros using Excel and Mathcad or similar softwareDocuments analyses in formal structural substantiation reports and other airworthiness documentsContributes to FAA STC Project Specific Certification Plans (PSCP)Interfaces with Design Engineers to determine structural load paths and design optimizationReviews & approves engineering drawings & reports • Attends design reviews as necessaryRegular and reliable attendance on a full time basis [or in accordance with posted schedule].Responsible for exhibiting professional behavior with both internal and external business associates that reflects positively on the company and is consistent with the company's policies and practices.Embodies AEVEX's cultural values and aligns daily actions with department goals and company culture.Qualifications and Competencies: Ability to obtain and maintain a Secret Security Clearance (US Citizenship required)Familiarity with resources such as MMPDS, Bruhn, Roark, etc., aircraft fasteners, materials, sheet metal assemblies, machined fittings, composites (fiberglass/carbon fiber), and honeycomb and solid laminate constructionKnowledge of and familiarity with 14 CFR Part 23 and Part 25 structures regulationsStrong foundation in technical skills, such as stress analysis, FEM, and solid modeling.Solid understanding of engineering modeling techniques and principlesExperience reviewing and interpreting engineering models, drawings and manualsStrong organizational, analytical and problem solving skillsAbility to evaluate, document, and report information regarding designs based on structural trade studiesExperience with sheet metal modeling techniques for aircraft structuresStrong communication skills, both written and verbal.Proficient in MS Office for report writing and analysis preparationAbility to work collaboratively with the engineering team and cross functionallyProficient in writing technical reports and presenting data in a clear and concise mannerDriven self starter with a strong sense of accountabilityEducation / Certifications: Degree in Aerospace or Mechanical Engineering or equivalent experience requiredExperience: 8-10 years of classical aircraft hand stress analysis methods and NASTRAN (FEMAP) finite element modelingExperience with primary & secondary structural modifications on aircraftPhysical Requirements: The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions. While performing the duties the employee is: Constantly required to sit, and to reach to use computers and other office equipment. For this summary, occasionally is used to represent up to 1/3 of the time given to the work day, frequently represents 1/3 to 2/3 of the time and constantly represents 2/3 or more of the time.AEVEX provides a reasonable range of compensation. Actual compensation is influenced by an array of factors including, but not limited to, skill set, level of experience, and specific location. The range of starting pay for this position is for the listed location only. Salary Range$200,000-$224,000 USDAbout AEVEX AEVEX, headquartered in Solana Beach, California, supports the U.S. national security mission and partner nation needs around the world by providing full-spectrum aviation, remote sensing, and analysis solutions. The company's capabilities include custom design and engineering; rapid prototyping; sensor integration and sustainment; aircraft modification and certification; flight test instrumentation and support; mission operations service; advanced intelligence data processing, exploitation, and dissemination solutions; and tailored hardware and software mission-system tools. AEVEX uses agile and customized approaches to rapidly define, develop, and deliver specialized solutions for airborne special mission needs for the U.S. Government, partner nations, and commercial businesses. AEVEX has major offices in California, Florida, North Carolina, Ohio, and Virginia.AEVEX provides a full suite of comprehensive benefits, including a 401(k)-retirement plan, comprehensive Medical, Dental, Vision, Disability and Life insurance group coverage with a portion of the premiums paid by the company, professional development funds, and an Employee Assistance Plan (EAP) with counseling, legal help, child and elder care support, among other benefits for qualified employees.Equal Employment Opportunity:AEVEX is an Equal Opportunity employer. We are committed to providing equal employment opportunities to all employees and applicants without regard to race, religious creed, color, sex (including pregnancy, breast feeding and related medical conditions), gender, gender identity, gender expression, sexual orientation, national origin, ancestry, citizenship status, military and veteran status, marital status, age, protected medical condition, genetic information, physical disability, mental disability, or any other protected status in accordance with all applicable federal, state and local laws.

Created: 2026-04-02