Principal Mechanical Engineer - Loads / Stress
Skills
About This Role
Key Responsibiities-
- Develop aircraft-level loads for UAV systems, including: Maneuver loads (limit and ultimate cases) ,Gust and turbulence loads (where applicable) ,Ground loads (landing, taxi, handling, transportation) ,Propulsion and system-induced loads (thrust, inertia, vibration drivers) Payload and mission-dependent loads
- Translate mission profiles and operational scenarios into design loads, working closely with Flight Mechanics, Aerodynamics, Systems, and Test teams.
- Define load cases, combinations, and envelopes, ensuring: Internal consistency across disciplines, Traceability to assumptions and mission definitions ,Practical usability by stress and design teams
- Establish and document loads methodologies, including: Assumptions and simplifications appropriate for UAV development ,Use of empirical data, hand methods, and analytical models , Clear definition of validity ranges and limitations
- Perform analytical and numerical loads analysis, using- First-principles calculations (free-body diagrams, inertia relief, load paths) Simplified models (beam models, lumped masses)FEM (primarily for load extraction and distribution, not detailed stress sizing)
- Provide load inputs to stress, design, and systems teams, including-Section loads, interface loads, and component-level loads ,Time histories or envelopes when required ,Clear definition of coordinate systems and reference conditions
- Support multidisciplinary integration, ensuring loads are aligned with: Mass properties and CG evolution, Control laws and flight envelope assumptions ,Structural layouts and load paths
- Contribute to test definition and correlation, including: Ground and flight test instrumentation strategies (strain gauges, accelerometers) Back-calculation of loads from test data ,Updating models and assumptions based on test evidence
- Act as a situational technical leader by driving resolution of ambiguous or conflicting inputs ,Challenging unrealistic assumptions ,Providing technically sound direction during design reviews and critical decisions
- Continuously improve engineering practices, contributing to: Loads process definition and refinement templates, calculation methods, and internal guidelines , Knowledge sharing across programs
Educational Background
- :
- Bachelor’s degree in Mechanical or Aerospace Engineering (Master’s or PhD preferred)
Professional Experience
- Strong understanding of aircraft loads development, including maneuver, gust, and ground loads
- Ability to translate real-world missions into engineering load cases, avoiding over-idealization
- Solid grasp of:
- Rigid-body dynamics and inertia effects
- Load paths and structural interaction
- Basic aeroelastic considerations (at least at conceptual level)
- Experience with: Analytical tools (Excel, Python, MATLAB or similar) FEM tools (ANSYS, NASTRAN, Abaqus) for load extraction and distribution
- Comfortable working with incomplete data, making justified engineering assumptions
Standards & Compliance
- Familiarity with aerospace standards (EASA, FAA, MIL-STD) as guidance frameworks, with the ability to scale and adapt them to UAV and non-certified platforms
Preferred Certifications
- Chartered Engineer (CEng) or Professional Engineer (PE) (nice to have)
- Experience contributing to internal methods, tools, or engineering processes
- #ADASI
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